Tapered cup and method of forming the same

ABSTRACT

A metal cup and method of forming the same is provided. Metal cups of the present disclosure comprise a plurality of thin, straight-walled sections and a tapered profile. A domed portion is provided in the bottom of the cup. The cup may comprise a disposable cup, a reusable cup, or a recyclable cup.

This U.S. Non-Provisional patent application claims the benefit of priority from U.S. Provisional Patent Application Ser. No. 63/323,331 filed on Mar. 24, 2022, and is related to U.S. patent application Ser. No. 16/214,477, which is a Continuation-in-Part of and claims the benefit of priority from U.S. patent application Ser. No. 15/811,032, filed Nov. 13, 2017, and claims the benefit of priority from U.S. Provisional Patent Application Ser. No. 62/455,697, filed Feb. 7, 2017, the entire disclosures of which are hereby incorporated by reference.

FIELD

The present disclosure relates generally to metal cups and methods of forming the same. More specifically, the present disclosure relates to beverage cups formed from a metal. Various embodiments of the present disclosure provide for a thin-walled beverage cup that is stackable with cups of similar construction.

BACKGROUND

Existing disposable beverage cups and drinking containers typically comprise a plastic material. Plastic cups are manufactured from injection molding or thermoforming operations, whereby many lightweight and disposable cups may be formed. Existing metallic beverage containers generally comprise drinking cans including an end closure secured to the upper end of a filled can.

U.S. Pat. No. 4,366,696 to Durgin et al., which is hereby incorporated by reference in its entirety, discloses a nestable can and method of forming the same from a blank. Durgin et al., however, fail to disclose various features of the present disclosure including, for example, a tapered or stepped geometry as shown and described herein and methods of forming the same.

U.S. Pat. No. 4,914,937 to Bulso et al., which is hereby incorporated by reference in its entirety, discloses a method of forming a tapered container. Bulso et al. provide a straight-walled cup and a method of forming the same, but is devoid of various teachings of the present disclosure.

U.S. Pat. No. 6,463,776 to Enoki et al., which is hereby incorporated by reference in its entirety, discloses a manufacturing method for bottle-shaped cans with a neck and shoulder portion. Enoki et al. fail to disclose various features and methods of the present disclosure. For example, Enoki et al. fail to provide a cup-shaped container with tapered, straight sidewalls.

SUMMARY

Accordingly, there has been a long-felt and unmet need to provide a metal cup that is reusable and recyclable. There has also been a need to provide a tapered metal cup that is stackable to enhance shipping and storing of a plurality of cups.

In various embodiments, a tapered metal cup is provided that comprises shallow wall angles. Shallow wall angles, at least as used herein, comprise wall angles that are less than 30 and preferably less than approximately 10 degrees as measured from a vertical center line or vertical axis of the cup. The angular sides and shallow wall angles of cups as shown and described herein allow for stackability of at least two cups, which provides advantages for shipping and storage. In some embodiments, wall angles are provided that are larger than 10 degrees. In some embodiments, wall angles are provided that are between approximately 1 and 20 degrees.

In various embodiments, metal cups are provided comprising thin-walled aluminum. Preferably, metal cups are provided comprising a recycled aluminum alloy. Various embodiments, including those comprising thin-walled aluminum provide cups that are lightweight, are formed of a recycled and/or recyclable material, and are more rigid, useful, and durable than conventional plastic cups, for example.

Embodiments of the present disclosure contemplate recyclable and/or reusable containers. In various embodiments, reusable cups are provided. As used herein, the term “reusable” generally refers to a container that can be reused one or more times and/or washed without significant degradation to the container(s). In some embodiments, reusability is achieved and provided by stable and robust coatings that are operable to withstand soap, detergent, and high heat commonly associated with dish washers and residential hot water heaters (e.g. 110-140 degrees Fahrenheit). In some embodiments, containers are provided that are intended to be recyclable and not necessarily reusable. For example, containers are contemplated with coatings that are not intended or sufficiently stable to withstand washing operations. Additionally, reusable cups are contemplated as being provided with enhanced structural rigidity to withstand multiple uses and/or washes. Rigidity is contemplated as being enhanced by mechanical strengthening (e.g. ribs and/or increased wall thickness). In some embodiments, wall thickness is selectively increased in specific regions.

In some embodiments, a metal cup is provided with a constant wall thickness along at least a portion of the cup. An incoming gauge of the cup is reduced to a thinner wall thickness in the sidewalls of the cup. Horizontally-extending steps or ribs preferably extend around an entire circumference of the cup, and are provided to add strength to the finished cup while maintaining a lightweight character of the cup. The steps or ribs are provided as transition points between sections of the finished cup having different diameters. Alternatively, a tapered cup is provided without ribs, where the cup comprises a relatively smooth and linear sidewall which extends from the upper end of the tapered cup to the closed lower end.

In some embodiments, one or more roll forming operations are performed to increase the strength of a cup. In various embodiments, one or more rolling operations are provided during the formation of a container and wherein two rollers are provided and one of the rollers comprises a mandrel. The rolling operation(s) increase stiffness in the metal by adding stress or pre-stressing the material. Rolling operation(s) of the present disclosure are also contemplate for the forming of ribs, reinforcing the container in specific locations, embossing the cup, proving rings or ribs in a sidewall or dome, and other features. Rings and ribs of the present disclosure may be provided as horizontal elements or may be provided at an angle relative to an axis of a container. Angled ribs or rings are contemplated as comprising helical, thread-like elements that provide strength and increase hoop strength and/or facilitate stacking or nesting of containers.

In various embodiments, a method of forming a metal cup is provided. In one embodiment, a method of forming a metal cup comprises feeding an aluminum coil into a cupping press and producing a straight-walled cup from a substantially circular blank cut from the aluminum coil. In some embodiments, the cup preferably has a constant wall thickness that is approximately equal to the incoming gauge of the aluminum. In other embodiments, cup side walls thicken during a cupper draw process. The cup is then fed into a bodymaker where the metal is redrawn and ironed. The cup is further formed by washing the cup, and decorating and/or coating an outside and an inside of the cup. In certain embodiments, at least a portion of the exterior of the cup is decorated with a color, a logo, or other visual information. Subsequent to washing and coating operations, a top edge of the cup is curled, partially curled, or throttled to eliminate the sharp edge that is formed by the press. The cup is then drawn down in diameter and multiple straight wall sections are formed. Each of the straight wall sections is expanded to a larger diameter using a die with a tapered profile. Finally, a bottom dome is provided in the bottom wall of the cup wherein the dome provides enhanced structural stability to the cup. In various embodiments, a dome is provided in the bottom of a metal cup to provide enhanced strength and stackability features. It should be recognized, however, that the term “dome” is not limited to any particular geometric shape and is contemplated as including, without limitation, conical and frustoconical “dome” members. The present disclosure contemplates that a central bottom portion of the cup is positioned vertically above a standing surface of the cup.

In various embodiments, cups are provided that comprise a non-constant wall thickness. It is contemplated, for example, that the wall thickness may vary throughout the cup and the thickness in a base of the cup may be different than a thickness at other regions of the cup (for example).

In another embodiment, a method is provided wherein a bodymaker step is eliminated in favor of multiple redraw steps after the cupper. In some embodiments, the cup maintains a constant wall thickness through the entirety of the container. In further embodiments, including “draw-redraw” embodiments, a wall thickness of the cup increases from the base of the cup to the open end of the cup (i.e. the wall thickness at the top of the cup is greater than at the bottom of the cup). During the drawing process, the metal is circumferentially compressed. The blankholder suppresses or reduces wrinkling and the metal deforms as the circumference decreases. However, as the volume of metal remains constant, the thickness must increase. In some embodiments, a cup formed of 0.0096 inch gauge incoming metal is redrawn twice and comprises a thickness at the top of the cup of about 0.0109 inches. This thickness may be increased by performing additional redraws.

In one embodiment, a method of forming a tapered metallic cup is provided, the method comprising the steps of providing a stock metal material; forming at least one cup using a blank and draw operation; performing a redrawing operation on the cup to provide the cup with a predetermined height and a wall thickness; subsequent to the redrawing operation, trimming the cup to a second height; curling the top edge of the trimmed cup to form a lip; forming one or more straight wall sections in the cup by drawing the cup; expanding each of the one or more straight wall sections using one or more dies with a tapered profile; and forming a dome in the bottom of the cup. In various embodiments, each cup section is expanded by not more than 15%, wherein percentage expansion is expressed as [(final diameter−initial diameter)/initial diameter]×100. In some embodiments, a cup is redrawn to form a final shape and without further forming. In such embodiments, it is contemplated that a wall angle of the cup is relatively low (e.g. less than degrees).

In another embodiment, a method of forming a tapered metallic cup is provided, the method comprising the steps of providing a stock metal material; forming at least one cylindrical preform from the stock material; trimming the cylindrical preform to a second height; curling a top edge of the trimmed cylindrical preform to form a lip; forming a cup by providing one or more straight wall sections in the cylindrical preform by drawing the preform; expanding each of the one or more straight wall sections to a larger diameter using one or more dies with a tapered profile; and forming a dome in the bottom of the cup.

Various embodiments of the present disclosure contemplate providing a curl at an upper portion or a lip of a cup. In some embodiments, the curl extends around an entire circumference of an upper lip of a cup. In alternative embodiments, an upper lip of a cup is not rotationally symmetrical. For example, a certain curl or edge treatment may extend along only a portion of a circumference of a lip of cup. Curls of the present disclosure are contemplated as being produced using a variety of methods. Curl geometry is contemplated as comprising variations in dimensions and/or profiles. Various curls are contemplated as being provided for creating various desirable effects including, for example, protecting a user from an otherwise sharp edge; providing a preferred seat or mating surface for a lid, top, or closure; shaping or controlling materials (e.g. liquids) as they are poured or otherwise exit a cup; aesthetic purposes; stackability; nesting; and product quality or performance (e.g. added strength at the lip). In preferred embodiments, curls are provided that extend away from a centerline of a cup to provide an outboard curl with an edge of the material provided external to the cup and preferably within or partially within a curl such that the edge is not exposed. In some embodiments, cups are made without a curl. For example, cups are contemplated as being provided that are devoid of a curl and which have edge that is exposed, dulled, or “uncurled.”

Curling operations, steps and processes are referred to herein as trim, curl, and/or curl and trim operations. Curling operations are contemplated as including, but are not limited to, single curl, double curl, reprofiled curl, shaped curl, throttled curl, tucked curl, rolled curl, smoothed curl, gorged curl, lugged curl and/or lipped curl. It will also be noted that these terms and various curl methods and steps provided herein are not mutually exclusive and a plurality of curl operations and steps are contemplated as being provided on a cup.

In various embodiments of the present disclosure, one or more trimming operations are provided in the formation of a cup. In some embodiments, a cutting or trimming is provided at an upper, open end of a cup. The cut or trim is contemplated as being perpendicular to a vertical axis of a cup in some embodiments. Alternatively, the trim or cut is contemplated as being provided between approximately 35 and 145 degrees. A pilot member is contemplated for use inside a cup and/or a guide is provided on the outside of the cup. A pilot and/or guide are generally used to control concentricity or rotational symmetry during a trimming process.

In some embodiments, a trim or trimming is performed by a single point shear method wherein a single blade or double blade is provided to cut and shear trim scrap from a top of a container. Initially, a single point is pinched or cut and the blade(s) rotates around the container to complete a trim. Finally, the trim is separated and removed as a hollow cylinder. Various trim knives or bits are contemplated for use to remove metal. One or more knives could be provided to generate a controlled edge without generating metal slivers or hairs. Pinch trim operations are also contemplated wherein a tooling gap between two tools is sufficiently small that the metal shears. In such cases, a hollow cylinder is removed at a controlled height on the container.

In one embodiment, a tapered metallic cup is provided. The tapered metallic cup comprises an upper end and a lower end, and a height extending between the upper end and the lower end. The upper end comprises a curled, partially curled, or throttled lip and an opening. A plurality of tapered sections are provided between the upper end and the lower end, with a step provided between each of the tapered sections. Each of the tapered sections comprises a wall thickness and a tapered profile. Wall thickness may vary within a given panel and/or across different portions of a cup. Adjacent tapered sections of the plurality of tapered sections comprise successively smaller diameters from the upper end to the lower end, and the step provided between each of the tapered sections comprises a transition in diameter.

In some embodiments, containers and cups of the present disclosure comprise a shape, geometry, or profile which enables stacking the cups and increases the ease with which stacked cups can be separated. Specifically, in certain embodiments, at least a lower portion of a cup comprises a profile as shown and described herein that reduces or prevents a vacuum, suction force or taper-lock/friction force (result of two tapered panels, or a tapered panel and vertical-walled panel pushing into one another) that otherwise tends to prevent or impede the separation of stacked cups.

Embodiments of the present disclosure provide for methods and systems for forming metallic cups. In some embodiments, methods and associated tooling are provided for forming cups with a feature or shape that reduce at least one of a vacuum force, a suction force, and a friction force that is provided between stacked cups at least when the stacked cups are pulled apart.

In some embodiments, anti-sticking features of the present disclosure provide for a cup geometry and an outer profile of a cup that enables a gap or separation to be provided between the curls of adjacent cups even when the adjacent cups are nested or stacked. This substantially prevents adjacent cups from sticking to one another and reduces the force required to separate adjacent cups. In certain embodiments, adjacent curls of stacked cups are provided with a gap of at least approximately 0.01 inches and 0.9 inches, and more preferably of about 0.35 inches, even when the adjacent cups are fully nested (i.e. one cup is completely inserted into the adjacent cup).

In one embodiment, a tapered metallic cup is provided that comprises an upper end, a lower end, and a height extending between the upper end and the lower end. The upper end comprises a curl, one or more tapered sections are provided between the upper end and the lower end, with a step provided between each of the tapered sections in embodiments comprising a plurality of tapered sections. Each of the tapered sections comprises a wall thickness and a tapered profile. Wall thicknesses of cups of the present disclosure are contemplated as comprising thicknesses between approximately 0.002 inches and 0.010 inches. Adjacent tapered sections of the plurality of tapered sections comprise successively smaller diameters, and the step provided between each of the tapered sections comprises a transition in diameter. The lower end of the cup comprises a domed portion, a first radius, an inwardly tapered sidewall, a second radius and a third radius. The first and third radii comprise convex features, and the second radius is provided between the first and third radii.

In one embodiment, a tapered metallic cup is provided that comprises an upper end and a lower end, and a height extending between the upper end and the lower end. At least one tapered section is provided between the upper end and the lower end. Each of the tapered sections preferably comprises a tapered profile. Adjacent tapered sections of the plurality of tapered sections comprise successively smaller diameters. The lower end of the cup comprises a stacking feature with a plurality of inflection points, the stacking feature comprising a first radius, an inwardly tapered sidewall, a second radius and a third radius. The first and third radii comprise convex features, and the second radius is provided between the first and third radii.

In one embodiment, a method of forming a tapered metallic cup is provided. The method comprises providing a stock material; forming at least one cup using a blank and draw operation; performing a redrawing operation on the cup to form a predetermined height and a wall thickness; subsequent to the redrawing operation, trimming the cup to a second height; curling the top edge of the trimmed cup to form a lip; forming one or more straight wall sections in the cup by drawing the cup; expanding each of the one or more straight wall sections using one or more dies with a tapered profile; forming a dome in a bottom of the cup; and forming an anti-sticking feature in the bottom of the cup by providing a compression force on the bottom of cup radially exterior to the dome such that a lower section of the cup comprises an inward taper or slope.

In one embodiment, a method of forming a tapered metal cup is provided comprising an initial step of feeding a coil into a cupping press and blanking and drawing a portion of material into a cup. Subsequently, the cup is at least one of drawn, ironed, trimmed, washed, dried, decorated, over-varnished, internally coated and bottom sprayed. A curl is then formed at an upper end or lip of the cup. At least one and preferably a plurality of draw stages are then performed wherein the cup is drawn to a larger height, and wherein the container is narrowed in at least one of the draw stages. Subsequent to at least one of the draw stages, at least one expansion step is performed by an expansion die (for example) to expand the width and diameter of the cup to a desired amount. A final step is contemplated as comprising a reverse taper step in which a reverse taper is formed in a bottom of the cup to form an anti-sticking feature that prevents or reduces cups from nesting or sticking when provided in a stacked arrangement. This final step, which is contemplated as being an optional step, renders adjacent stacked cups to be easier to extract or separate.

In various embodiments, methods, systems and devices for cup stacking features are provided to reduce a force required to separate cups from a stacked arrangement. In some embodiment, cups are provided with geometry and features to prevent an extent or amount to which cups “nest” or extend into one another. Such features reduce a force required to separate the cups. In some embodiments, an outward projection is provided that is greater in diameter than a panel or section of a cup upon which the projection is provided. The outward projection provides a resting surface or contact point which prevents a bottom of a cup from contacting or extending down to the bottom panel of an adjacent cup. Outward projections of the present disclosure are contemplated as being provided on any one or more cup panels or segments. In some embodiments, it is contemplated that an outward projection is provided on an uppermost panel or segment. Preferably, the outward projection(s) comprise an annular element that extends completely around a circumference of a cup and comprises a rotationally symmetric feature. In alternative embodiments, however, it is contemplated that the projection(s) extend around less than an entirety of a cup circumference.

It is an object of the present disclosure to provide a stacking or nesting feature that reduces separation force between cups without significantly increasing “stack height” or the total amount of height provided by two stacked cups. The present disclosure contemplates providing a stacking feature or projection on at least one cup panel, and wherein the height of the cup panel that comprises such a feature can be altered to control or determine stack height.

In one embodiment, a tapered metallic cup is provided that comprises an upper end and a lower end, and a height extending therebetween. The upper end comprises a peripheral curl, and a plurality of panels is provided between the upper end and the lower end, with a transition provided between each of the panels. Adjacent panels of the plurality of panels comprise successively smaller diameters, and the transition provided between each of the panels comprises a transition in diameter of the cup wherein cup sections are preferably smaller in diameter toward the bottom of the cup. A semiannular projection is provided that extends along at least a portion of a circumference of the cup.

Stacking and anti-sticking features are provided herein. In some embodiments, a reverse-taper feature is provided at a lower end or bottom of a cup. In further embodiments, at least one of an outwardly and inwardly projection is provided that is/are operable to provide a diameter or bulge that is operable to contact an adjacent cup. It is specifically contemplated that one or more of these feature is provided within a single cup. Accordingly, stacking and anti-sticking features are not mutually exclusive. While is contemplated that cups are provided with a single anti-sticking or stacking feature as shown and described herein, it is further contemplated that cups are provided with multiple features that are shown and described herein, even if a specific combination is not shown in the Figures.

While various embodiments of the present disclosure comprise a cup with an upper end having a curl, the present disclosure is not limited to such embodiments. It is contemplated, for example, that cups according to various embodiments of the present disclosure do not comprise a curl at an upper or drinking end. For example, in some embodiments, an upper end of a cup comprises an edge that is not curled. The edge may be shaped with a lip roller and/or may be provided with a covering or cap. In some embodiments, an upper edge or lip of the cup is not treated, curled, or rolled. It is further contemplated that lugs or protrusions are provided on a lip. For example, lugs or protrusions for interfacing with a lid are contemplated as being provided at an upper end of the cup.

In some embodiments, a lip roller is provided to roll form a curl on an upper end of a cup. It is also contemplated that multiple rollers are provided to tuck and roll an upper edge of the cup. The cup(s) and/or tool may be heated to facilitate such operations. In some embodiments, upper ends of cups are rolled or formed while the cups are in a stacked arrangement. Additional curl forming methods and features are also contemplated in embodiments of the present disclosure. For example, methods of forming a curled and strengthened top of a cup as shown and described in Japanese Patent Application JP2004291566 to Sakuma, which is hereby incorporated by reference in its entirety, are contemplated as being provided with cups of the present disclosure.

In some embodiments, a safety seam or safety fold is provided at the upper end of the cup. The safety seam may comprise various different configuration including one or more folds, curls, or seams to convert or shape a thin or sharp metal edge to a surface or edge that is not abrasive and does not pose laceration risks to a user.

In various embodiments, it is contemplated that containers of the present disclosure are provided with a double curl wherein the lip is curled or rolled down more than once. The double curl is operable to receive an additional component (e.g. a lid) and to protect a user during drinking. Curls, including double curls are contemplated as being oriented inwardly or outwardly.

In some embodiments, cups of the present disclosure are contemplated as comprising various decorations and graphics. Various known inking and decorating steps are contemplated as being provided to stock material and containers of the present disclosure. U.S. Patent Application Publication No. 2019/0283489 to Dominico et al., which is hereby incorporated by reference in its entirety, discloses methods and systems for decorating cups. In some embodiments, graphics are provided on various portions of a cup including the dome, interior of the cup, and on one or more outer panels of the cup. Ink and decoration are contemplated as being provided on cups of the present disclosure at various stages of the cup formation process. Ink may be provided to raw material (aluminum sheet(s), a finished or formed cup, and at various stages therebetween.

Cups and containers of the present disclosure are contemplated as comprising various decorations, indicia, and added features. For example, in some embodiments, cups of the present disclosure comprise decorative inks known in the art including those discussed in U.S. Patent Application Publication No. 2019/0283489 to Dominico et al. Cups and containers of the present disclosure are also contemplated as comprising tactile inks, thermochromic inks, radio-luminescent inks, and other inks. Additionally, stickers, badges and emblems are contemplated as being provided on a cup. In some embodiments, a “badge” is provided that is formed of metal or is 3D printed to form a component that is welded or adhered to cup(s) after the cup(s) are formed. In further embodiments, shapes, logos, writing or indicia are etched or laser scribed into a formed cup or cups. It is also contemplated that stickers and peal-away stickers are provided on cups. Bar codes and QR codes are examples of indicia or information that are contemplated as being provided on cups of the present disclosure through any one or more of the aforementioned methods of printing or adding information.

Various methods of forming cups are contemplated. While certain embodiments of the present disclosure contemplate drawing operations for forming cups, additional and alternative embodiments contemplate forming a cup by one or more of: impact extrusion, spin forming, blow molding, multi-piece construction and assembly, draw and redraw, deep draw, and other methods.

In some embodiments, cups are forming using metal spinning techniques. A blank or disc of metal is contemplated as being spun or rotated at a high speed and formed into an axially symmetrical part. Such processes may be performed on a lathe or similar tool. In some embodiments, a plurality of cups is formed simultaneously on a single lathe or other rotational tool.

Cups of the present disclosure are contemplated as being made from various metals including but not limited to steel, tin plated steel, tin free steel and aluminum. The metal is contemplated as being uncoated or lightly lubricated. The incoming metal may be precoated with a polymer film. This film may be applied to the coil as liquid coating that is subsequently cured. These coatings are generally polymeric resin coatings within the epoxy, acrylic or polyester families. Alternatively, the pre-applied film may also applied by laminating with solid resin film. The film may be polyester or polyolefin. These films are often of multilayers to optimize adhesion and product protection. Such coatings are provided to optimize adhesion on the surface contacting the metal. A product protection optimized layer is provided in various embodiments.

In various embodiments, methods of forming a container are provided that comprise feeding a coil of metal into a press. In certain embodiments, a punch and blank and draw die cuts a circular blank. The blank may alternately be non-round to accommodate material anisotropy. In the same stroke, a die center cooperates with a drawing die to draw the cup. This cup is contemplated as being ejected thought the bottom of the die. Multiple tool sets are contemplated as being installed in the press to allow simultaneous forming of multiple cups.

The initial cup form is conveyed to and loaded into a redraw press. A blankholder/cupholder enters the cup and places it in contact with a redraw die. Pneumatic pressure is used to control the force between the cupholder and the redraw die. Alternatively, spring and cam driven hold down means are contemplated as well as other suitable methods. A punch moves through the hollow cupholder, contacting the cup and redraws the initial cup through the redraw die, creating a second stage cup. The second stage cup is smaller in diameter and taller than the initial cup form. When the material is drawn into the redraw die, compressive strains cause the material to thicken. The radial gap between the punch and the redraw die is preferably greater than the thickness of the redrawn metal. Use of small draw radii and high blankholder force is contemplated as resulting in some stretching of the cup sidewall.

The process to progress from an initial cup to a second stage cup may be repeated to create increasingly smaller diameter and taller containers. A high number of redraws may necessitate a trimming operation to remove earing resulting from planar anisotropy of the redrawn material. In some embodiments, a final redraw step is contemplated as comprising a tapered punch, smaller at the nose, resulting in a tapered finished cup.

A final redraw may be complete, that is the entire flange is drawn into the die, or incomplete, leaving a portion of the flange in the plane perpendicular to the cup axis. In either case, the flange is shaped in additional operations as described herein.

A profile is contemplated as being formed in a bottom of a cup in various processes and methods of the present disclosure. The bottom profile is preferably formed at the end of the forming stroke in a final stage.

Diametric reductions become more limited with additional drawing and redrawing steps. For manufacturing efficiency, the highest possible diametric reductions should be taken to achieve the desired height and diameter. Therefore, the low end of the allowable reduction range is of minimal importance. The maximum diametric reductions for aluminum are contemplated in various embodiments as: blank to initial cup form: 40-50%; initial cup form to second stage cup: 30-40%; and second stage cup to third stage cup: 20-35%. The radius over which the material draws in is in the range of 0.040″ to 0.150″ and preferably of about 0.060″ to 0.120″.

In some embodiments, cups are formed using impact extrusion methods. In such embodiments, a slug is provided and is contemplated as being pressed at high velocity and force to form a cup. The slug may be driven by a punch into a die or mold to form the cup. In such methods and embodiments, cups are formed with a single panel or section or may be formed with a plurality of panels or sections and wherein a plurality of impact extrusion steps are provided. Cups of the present disclosure (regardless of formation method) are not limited in the number of panels or sections they may comprise. Cups and containers are contemplated with as few as a single section and as many as 1,000 sections. Single panel cups formed by impact extrusion are contemplated as comprising a cylindrical cup with a vertical, non-tapered sidewall. Single panel cups are also contemplated as being formed as tapered in an initial mold step and/or with additional steps. It is further contemplated that any desired tapered is subsequently provided or formed using various methods and tooling shown and described herein.

In various embodiments, a seamed sidewall is provided in a cup. For example, in some embodiments, a cup is formed by wrapping or shaping a sheet of metal and seaming the ends together to form a vertical seam that seals the container. Such seams are contemplated as comprising a mechanically folded seam, a weld, a laser weld, a flash butt weld, or other weld, a double seam, or adhered in various ways.

Various embodiments of the present disclosure contemplate working material and forming containers by coining. As will be recognized by one of ordinary skill in the art, coining comprises subjecting metal (e.g. aluminum) to sufficiently high stress to induce plastic flow and in some embodiments reduce grain size.

In some embodiments, a cup is formed by performing a necking operation. It is contemplated, for example, that a cup is formed through one or more methods described herein and the bottom (closed end) of the cup is cut off. The open bottom is then necked and a seamed end (e.g. double-seamed end closure) is provided to reclose the bottom.

It is further contemplated that cups are formed by providing a plurality of different cup walls or sections. The multiple pieces can be arranged and secured together (e.g. by welding) to provide a formed, finished cup.

In some embodiments, cups of the present disclosure are formed using blow mold formation techniques. Blow molding or blow forming is contemplated to form metal cups as shown and described herein. Extrusion blow molding, for example, is contemplated as being provided to form a metal cup by forcing metal or other material into a mold comprising a desired shape of the cup.

In various embodiments, cups of the present disclosure are forming using a draw and redraw process (“DRD”). DRD processes are contemplated as providing a metal container or cup. Such processes are contemplated as comprising steps of cutting a blank from a sheet, drawing the blank through a die to form a first stage of a cup, and then redrawing the cup to form a can of a desired height and diameter.

In certain embodiments, metal cups of the present disclosure are formed using a deep draw method. For example, it is contemplated that one or more deep drawing processes are provided to work a sheet of metal (e.g. aluminum) into a cup using a punch. The depth of the drawn part during this process exceeds the diameter of the cup. For example, during the formation of a metal cup with a height of six inches, the draw length comprises more than six inches. Additional processes are contemplated as being combined with deep drawing methods. For example, one or more deep drawing steps are contemplated as being performed, and expansion steps are provided after deep drawing.

In some embodiments, various single panel cups are provided. In some embodiments, small (e.g. 10 ounce or smaller) cups are provided comprising a single panel. These cups may be formed using a redraw cupper. In some embodiments, single-panel cups comprise a thicker wall thickness for rigidity.

Various embodiments of the present disclosure contemplate the provision of welding to form or finish cups of the present disclosure. For example, cups are contemplated as being formed and sealed or finished by providing at least one weld vertically along a side of a cup and/or by welding a bottom (e.g. closure) to an open end of a container.

In various embodiments, cups are provided with a profile and feature in the lower portion of the cup. In some embodiments, the cup profile comprises a “reverse-taper” wherein a wall section is angled (i.e., the lower portion of the section is of greater diameter than an upper portion of the same section). Such embodiments provide for stacking features as shown and described herein. Additionally, such features provide for a stabilization or fixing of a domed portion of the cup.

In various embodiments, the formatting of an anti-sticking feature or reverse taper imparts a biaxial strain across a bottom of the container. This strain pulls excess or loose material into a taught section of metal. This taught section is less susceptible to “oil-canning,” a condition wherein a domed, convex or concave feature has a tendency to invert itself (i.e. concave to convex and vice-versa). By putting the bottom or dome in biaxial tension, this area exhibits less springbuck or oil-canning tendency.

It is an object of the present disclosure to provide a tapered metal cup with enhanced rigidity. In some embodiments, cups are provided with various features to enhance the rigidity or stiffness of the cup and various panels or sections thereof. In some embodiments, cups are provided with ribs to enhance structural integrity. Such ribs may be shaped, formed, or provided as horizontally extending ribs along a circumference (or portion thereof) of a panel. These ribs are contemplated as being provided in addition to steps or transitions between tapered sections (where present). Additionally, the present disclosure contemplates embodiments with vertically extending ribs to enhance stiffness. Such ribs may be provided along a length of a cup and across transitions or steps or may extend along specific sections of a tapered cup. It is also contemplated that features may be embossed or debossed to enhance the rigidity of one or more panels.

Certain embodiments of the present disclosure contemplate providing embossing for decorative purposes. For example, in some embodiments, metal cups of the present disclosure are provided with embossed features (e.g. logos, emblems, text, etc.) on a cup. In some embodiments, embossing is provided as a final or near final step in a cup manufacturing process. Embossing prior to drawing or expanding, for example, may result in deformation of the embossed feature. However, in some embodiments, embossing is performed prior to drawing, redrawing and/or expanding the cup to achieve a desired result.

Cups of the present disclosure are contemplated as comprising various wall thicknesses. It should be recognized that cups of the present disclosure are not limited to a certain wall thickness. Additionally, the present disclosure is not limited to cups having a single or consistent wall thickness. It is contemplated, for example, that cups of the present disclosure comprise varying wall thickness along a height of the cup and/or along the height a cup section or segment. In some embodiments, wall thickness is contemplated as being greater at the bottom of the cup than the top and increasing in thickness as one travels from the top to the bottom to provide a lower center of gravity of the cup and reduce tipping of the cup.

It is an object of the present disclosure to optimize metal usage and provide for different metal thicknesses for different locations and features of a container. Processes and methods of the present disclosure provide for a change in wall thickness during a draw-redraw operation wherein a wall thickness of a drawn container (or at least a portion thereof) will be different from the incoming container. Additionally, methods and systems of the present disclosure contemplate the provision of a “rework taper” wherein incoming metal with an initial gauge (e.g. 0.003-0.030 inches and preferably of between about 0.096 inches) in a base portion and a transition to a wall thickness portion on the ironed container (e.g. 0.002-0.030 inches and preferably of between about 0.0070 and 0.0030 inches). For example, in embodiments wherein a metal thickness in the base portion is approximately 0.096 inches and the thickness in a wall portion is approximately 0.0060 inches, a gradual transition or taper is provided between these two thicknesses. This taper or “rework taper” is contemplated as being a linear gradual transition, but alternatives are contemplated. Variations in wall thickness are contemplated to: decrease metal thickness and save material and cost; strengthen specific features and portions of a cup (e.g., the curl or top panel); weaken specific portions or features (e.g. lids or tear-away portions); and provide for various ergonomic features and benefits.

In one embodiment, a container is provided with a dome in the bottom of the cup comprising a first thickness (T_(d)). Adjacent panels extending from the dome comprise varying wall thickness.

In some embodiments, lower panels comprise varying wall thicknesses along their length and upper panel(s) comprise a substantially consistent thickness that is less than the lower wall thicknesses. An uppermost panel is contemplated as comprising a curl and comprise a thicker wall thickness (at least relative to the lowermost panel thickness(es)) for providing curl stability. In certain embodiments a transition from thin to thick wall thickness is provided in a second uppermost panel to transition from a thinwalled middle portion of the cup to a thick uppermost portion to support the curl and drinking operations, and to prevent denting on the top most panel. Additionally, thick sections are contemplated as being provided in various areas or sections of a cup. For example, it is contemplated that a transition from a thin wall section to a thick wall section is provided and the thick wall section transitions back to a thin wall section. This is contemplated, for example, at a step or transition wherein the thickness of the wall is variable and increases to provide additional support to a specific portion of the cup.

In some embodiments, methods of forming metal cups are provided that comprise a step of preforming a base of the container. In certain embodiments, a base of a container or cup is preformed and surplus metal material is provided in the base. The surplus material is then available for use as the container is further formed or worked (e.g. drawn).

In some embodiments, cups of the present disclosure are provided with relief features, shaping or “restricking.” Features and methods of forming such features are shown and described, for example, in U.S. Pat. No. 9,358,604 to Jentzsch et al., which is hereby incorporated by reference in its entirety. The methods and tooling disclosed in U.S. Pat. No. 9,358,604 are contemplated as being applied or used with cups of the present disclosure.

Although various embodiments of the present disclosure contemplate and provide round cups that are rotationally symmetrical, the present disclosure is not limited to such embodiments. For example, various non-round cup shapes and container shapes are contemplated. Square and/or rectangular cups are contemplated and are formed from bending and/or dies and tooling that are not round. In some embodiments, a non-round container is formed by bending a sheet of material into a desired shape (comprising four sides, for example) and securing a bottom by at least one of seaming and welding the bottom to the container. Non-round containers can also be formed by draw and redraw processes from blanks. These containers are contemplated as being formed from tooling (e.g. dies) with one or more stiffening beads, drawbeads, or other methods known in the art and to help control or retard the flow of metal during forming.

In various embodiments, containers of the present disclosure are provided with a bottom having an upstanding dome portion. The dome portion is surrounded by an annular standing surface. In some embodiments, a plurality of feet or lugs are provided in at least one of the dome portion and the annular standing surface. For example, in certain embodiments, three or more protruding feet are formed in the device and extend from the annular standing surface.

Domes of the present disclosure are contemplated as comprising convex features that extend upwardly into an interior volume of the cup. In some embodiments, it is contemplated that sidewalls and domes of the cups of the disclosure comprise features, indicia, and/or ornamentation. For example, it is contemplated that a dome can be embossed or reformed to provide certain shapes and features on the dome (e.g. logos at the bottom of a cup). Domes of the present disclosure (and other portions of a cup) are contemplated as being coined, embossed, or debossed to provide shapes and features in the dome.

While preferred embodiments of the present disclosure contemplate the use of aluminum and pre-coated aluminum, it should be recognized that the present disclosure and containers described herein are not limited to any particular metal, coating, or coated metal. In some embodiments, a base coat is applied to a cup or container prior to decorating. In some embodiments, a base coat is provided that comprises a full color (e.g. white) coating that is applied before decorating and is cured in an oven. The base coat is contemplated as being applied by an applicator roll as a consistent coat at a consistent thickness around the outside of the container. Coating and painting may also be applied by spraying, electrostatic application, etc.

Although various embodiments of the present disclosure contemplate cups and containers with domes, the present disclosure is not limited to containers with such a feature. It is also contemplated that cups of the present disclosure are provided with a flat bottom that is devoid of an upstanding dome.

In various embodiments, insulated containers are provided. In some embodiments, it is contemplated that two or more cups in accordance with any one or more of the embodiments of the present disclosure are provided. Preferably, one cup is of smaller dimension(s) than another cup. The plurality of cups are nested and connected (e.g. double seamed together at the upper end of the cups) to form a finished cup. It is contemplated that an insulating material is provided between the two cups. Insulating materials of the present disclosure include but are not limited to ambient air, argon, Styrofoam, and various combinations thereof.

Cups and containers of the present disclosure are contemplated as being made from various metals including steel, tin plated steel, tin free steel and more preferably aluminum. The metal may be uncoated or lightly lubricated. The incoming metal may be precoated with a polymer film. This film may be applied to the coil as liquid coating that is subsequently cured. These coatings are generally polymeric resin coatings within the epoxy, acrylic or polyester families. Alternatively, the pre-applied film may also applied by laminating with solid resin film. The film may be polyester or polyolefin. These films are often of multilayers to optimize adhesion and product protection. A layer with optimize adhesion is provided on the surface contacting the metal. A product protection optimized layer is away from the metal.

In one embodiment, a method of forming a cup is provided that comprises: providing a coil or quantity of raw metal into a press. A punch and blank and draw die is provided to cut a circular blank from the coil. The blank is contemplated as being non-round in alternative embodiments to accommodate material anisotropy. In the same stroke, a die center cooperated with a drawing die to draw an initial cup form. This initial form is contemplated as being ejected through the bottom of the die. Multiple tool sets are contemplated as being installed in the press to allow simultaneous forming of multiple initial cup forms. The initial cup is conveyed to and loaded into a redraw press. A blankholder or cupholder is used to control a force between the cupholder ad a redraw die. A punch moved through the hollow cupholder and contacts the initial cup form and redraws the initial cup form through the redraw die, creating a second stage cup. The second stage cup is smaller in diameter and taller than the initial cup form. The material is drawn into the redraw die and compressive strains cause the material to thicken. A radial gap between the punch and the redraw die is greater than the thickness of the redrawn metal in some embodiments. Use of small draw radii and high blankholder force may result in some stretching of the cup sidewall. The process of forming an initial cup to a second stage cup can be repeated to create increasingly smaller diameter and taller containers. A high number of redraws is contemplated and may necessitate a trimming operation to remove earing. A final redraw step comprises a tapered punch to form a tapered, final cup. The final redraw may comprise a combined or single step, or may comprise a plurality of redraw steps. A final redraw may be complete (i.e. the entire flange is drawn into the die) or a portion of the flange may be left perpendicular to the top of the cup. The flange is shaped in additional operations as shown and described herein. Diametric reductions become more limited with additional drawing and redrawing steps. For manufacturing efficiency, the maximum diametric reductions for aluminum are contemplated in some embodiments as: blank to initial cup: 40-50%; initial cup to secondary stage cup: 20-30%; second stage to third stage cup: 15-30%. The radius over which the material draws in in the range of 0.040″ to 0.150″, more preferably 0.060″ to 0.120″.

While various embodiments of the present disclosure contemplate containers and cups with a plurality of sections or panels, further embodiments contemplate containers or cups that are devoid of steps or transitions and generally comprise a single panel or a single angled straight-walled section. The straight-walled section may be tapered. Single panel cups of the present disclosure are contemplated as being formed by various methods and techniques including, for example, blank-and-draw (or “deep draw”) impact extrusion and spin forming methods.

The Summary of the Invention is neither intended nor should it be construed as being representative of the full extent and scope of the present disclosure. The present disclosure is set forth in various levels of detail in the Summary as well as in the attached drawings and the Detailed Description and no limitation as to the scope of the present disclosure is intended by either the inclusion or non-inclusion of elements, components, etc. in this Summary. Additional aspects of the present disclosure will become more readily apparent from the Detailed Description, particularly when taken together with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Those of skill in the art will recognize that the following description is merely illustrative of the principles of the disclosure, which may be applied in various ways to provide many different alternative embodiments. This description is made for illustrating the general principles of the teachings of this disclosure and is not meant to limit the inventive concepts disclosed herein.

The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the disclosure and together with the general description of the disclosure given above and the detailed description of the drawings given below, serve to explain the principles of the disclosure.

It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary for an understanding of the disclosure or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the disclosure is not necessarily limited to the particular embodiments illustrated herein.

FIG. 1 is a front elevation view of a container body in one stage of formation and according to one embodiment of the present disclosure.

FIG. 2 is a front elevation view of a container body in one stage of formation and according to one embodiment of the present disclosure.

FIG. 3 is a front elevation view of a metal container according to one embodiment of the present disclosure.

FIG. 4 is a front elevation view of a stackable metal container according to one embodiment of the present disclosure.

FIG. 5 is a cross-sectional elevation view of the container according to the embodiment of FIG. 4 and taken at section A-A.

FIG. 6 is a top plan view of the container according to the embodiment of FIG. 4 .

FIG. 7 is a detailed elevation view of a portion of multiple containers stacked according to one embodiment of the present disclosure.

FIG. 8 is a detailed elevation view of a portion of a container according to one embodiment of the present disclosure.

FIG. 9 is a detailed elevation view of a portion of a container in accordance with the embodiment of FIG. 4 .

FIG. 10 is a flow chart depicting a method of forming a metal cup according to one embodiment of the present disclosure.

FIG. 11 is a flow chart depicting a method of forming a metal cup according to one embodiment of the present disclosure.

FIG. 12 is a flow chart depicting a method of forming a metal cup according to one embodiment of the present disclosure.

FIG. 13 is a flow chart depicting a method of forming a metal cup according to one embodiment of the present disclosure.

FIG. 14 is a flow chart depicting a method of forming a metal cup according to one embodiment of the present disclosure.

FIG. 15A is a cross-sectional elevation view of a cup according to an embodiment of the present disclosure.

FIG. 15B is a detailed view of the lower portion of the cup of FIG. 15A.

FIG. 16A is a cross-sectional elevation view of a cup according to an alternative embodiment of the present disclosure.

FIG. 16B is a detailed view of the lower portion of the cup of FIG. 16A.

FIG. 17 is a cross-sectional view of a plurality of cups provided in a stacked or nested arrangement.

FIG. 18 is a cross-sectional view of tooling components according to one embodiment of the present disclosure.

FIG. 19 is a cross-sectional view of the tooling components of the embodiment of FIG. 18 .

FIG. 20 is a cross-sectional view of cups of the present disclosure according to one embodiment.

FIG. 21 is a detailed cross-sectional view of a feature of a cup according to one embodiment of the present disclosure.

FIG. 22 is a cross-sectional view of cups of the present disclosure according to one embodiment.

FIG. 23 is a detailed cross-sectional view of a feature of a cup according to one embodiment of the present disclosure.

FIG. 24 is a cross-sectional elevation view of a container according to one embodiment of the present disclosure.

FIG. 25 is an elevation view of a container according to one embodiment of the present disclosure.

FIG. 26A is a perspective view of a tooling component according to embodiments of the present disclosure.

FIG. 26B is a detailed cross-sectional elevation view of the tooling component of FIG. 26A.

FIG. 26C is a cross-sectional elevation view of the tooling component of FIG. 26A.

FIG. 27A is a cross-sectional elevation view of a container according to one embodiment of the present disclosure.

FIG. 27B is a cross-sectional elevation view of a container according to one embodiment of the present disclosure.

FIG. 28 depicts a plurality of forming processes for containers of the present disclosure.

FIG. 29 is a process diagram for a process of forming a container according to embodiments of the present disclosure.

FIG. 30 depicts a plurality of forming processes for containers of the present disclosure.

FIG. 31 is a process diagram for a process of forming a container according to embodiments of the present disclosure.

FIG. 32 depicts a plurality of forming processes for containers of the present disclosure.

FIG. 33 is a process diagram for a process of forming a container according to embodiments of the present disclosure.

FIG. 34 depicts a plurality of forming processes for containers of the present disclosure.

FIG. 35 is a process diagram for a process of forming a container according to embodiments of the present disclosure.

FIG. 36 is a cross-sectional elevation view of a portion of a cup according to embodiments of the present disclosure.

FIG. 37 is a cross-sectional elevation view of a portion of a cup according to embodiments of the present disclosure.

FIG. 38A is a perspective view of screw curling tooling according to an embodiment of the present disclosure.

FIG. 38B is a plan view of tooling according to an embodiment of the present disclosure.

FIG. 38C is a plan view of tooling according to an embodiment of the present disclosure.

FIG. 39A is a cross-sectional elevation view of a curled lip according to an embodiment of the present disclosure.

FIG. 39B is a cross-sectional elevation view of a curled lip according to an embodiment of the present disclosure.

FIG. 39C is a cross-sectional elevation view of a curled lip according to an embodiment of the present disclosure.

FIG. 40 provides a plurality of cross-sectional elevation views of curled lips of containers according to various embodiments of the present disclosure.

DETAILED DESCRIPTION

FIG. 1 is a front elevation view of a straight-walled preform 2. The preform 2 represents an initial forming stage of a metal cup according to one embodiment of the present disclosure. The straight-walled preform 2 is preferably formed by feeding a quantity of metal (e.g. aluminum) into a cupping press and forming a preliminary drawn cup from a blank sheet cut from a coil of metal material. The resulting straight-walled drawn cup preferably comprises a wall thickness that is approximately equal to or slightly greater than the incoming gauge of the metal fed into the cupping press. For example, in some embodiments, the wall thickness in the bottom of the cup comprises a thickness that is approximately equal to the incoming gauge. The preliminary drawn cup is then fed into a bodymaker wherein the metal is ironed. In some embodiments, the bodymaker performs a redraw operation that further reduces a dimeter of the cup before ironing. The resultant straight-walled preform 2 comprises a sidewall where the base comprises a thickness approximately equal to an incoming gauge of metal, and the sidewall in some embodiments comprises a varying sidewall thickness to optimize the performance characteristics of the cup, rigidity for instance. Variable wall thickness can also reduce the total mass of aluminum in the cup, providing for less material (e.g. aluminum) and related sustainability and cost benefits. In some embodiments, the thin-wall portion is not provided. The straight-walled preform 2 comprises an initial diameter Di that generally corresponds to and is approximately equal to the diameter of the punch that forms the cup. In various embodiments, the initial diameter Di is between approximately 2.0 inches and 6.0 inches. In preferred embodiments, the initial diameter Di is between approximately 2.5 and 5.0 inches, and more preferably is of approximately 2.865 inches in one embodiment and approximately 3.625 in a further embodiment.

The straight-walled preform 2 comprises a height H1 of between approximately 3.0 and 10.0 inches. In preferred embodiments, the preform 2 comprises a height H1 of between approximately 3.5 and 5.5 inches, and more preferably of between approximately 3.7 and 4.2 inches. A bottom portion of the preform comprises a radius of curvature resulting from the shape and contact of the punch used to form the cup. In various embodiments, this radius R is between approximately 0.025 inches and 0.250 inches, and preferably of between approximately 0.080 inches and 0.100 inches.

FIG. 2 is a front elevation view of a curled preform cup 4 in a further phase of the formation. The curled preform 4 of FIG. 2 comprises the thin-walled preform 2 of FIG. 1 , and wherein a curl 6 is provided on the upper edge or lip of the cup. The curl 6 is provided to eliminate a sharp edge, provide added rigidity, accommodate an attachable lid, and provide a means for removal from draw tooling. As shown in FIG. 2 , the curled preform cup 4 comprises a reduced height as compared to the preform 2 of FIG. 1 . Specifically, the curled preform cup 4 of FIG. 2 comprises a height H2 of between approximately 3.5 and 5.5 inches, but no limitation with respect to cup height is provided.

Prior to or subsequent to the forming of the curl 6, the preform 4 may be washed, coated, and/or decorated. It is contemplated that at least one of the inside and the outside of the preform is coated with epoxy resin and/or other materials that will be recognized by one of ordinary skill in the art. The cup is coated to protect the aluminum from oxidization and to prevent corrosion of the aluminum from the cup contents and avoid the aluminum imparting undesirable flavors to the beverage. It is further contemplated that an inside and/or outside of the cup is provided with paint or other ornamental treatment. Coating is contemplated as being provided to facilitate metal forming by reducing friction during forming steps.

FIG. 3 is a front elevation view of a straight drawn cup 8 according to one embodiment of the present disclosure and formed from the curled preform cup 4 of FIG. 2 . As shown, the straight drawn cup 8 comprises a curl 6 at an upper end or lip of the cup.

The straight drawn cup 8 further comprises a plurality of sections 10 a, 10 b, 10 c, 10 d, 10 e wherein the sections each comprise straight-wall sections of successively smaller diameter and varying height, as shown in FIG. 3 . FIG. 3 , as well other Figures of the present disclosure, are provided with dimensions. These dimensions are provided by way of example only and illustrate cups and features according to certain embodiments. It will be expressly recognized that devices, inventions and features of the present disclosure are not limited to the dimensions provided in the drawings, and various modifications and proportions are contemplated. The straight drawn cup 8 of FIG. 3 comprises an intermediate phase of the forming process of a cup of the present disclosure.

As shown in FIG. 3 , the straight drawn cup 8 comprises a plurality of sections 10, wherein each of the sections 10 comprise a successively smaller diameter from an upper end to a lower end of the straight drawn cup 8, wherein the uppermost section 10 a comprises the largest diameter, and the lowermost section 10 e comprises the smallest diameter. The sections comprise varying heights, wherein the relative heights in some embodiments can be characterized as: 10 c>10 d>10 b>10 e>10 a. As shown in FIG. 3 , the straight drawn cup 8 comprises five sections and four ribs. The number of sections and ribs may vary depending on consumer requirements. The section heights may also vary depending on consumer requirements.

FIGS. 4-5 illustrate a tapered metallic tapered cup 20 according to one embodiment of the present disclosure. The tapered cup 20 is preferably formed from the straight drawn cup 8 of FIG. 3 by expanding each of the straight walled sections 10 to a larger diameter (as compared to that shown in FIG. 3 ) using a die (not shown) with a tapered profile.

As further shown in FIG. 4 , the finished tapered cup 20 is drawn and expanded (FIG. 3 , for example) to a final height H3 that is greater than H2. Specifically, the finished tapered cup 20 comprises a height H3 that is between approximately 4.0 and 6.50 inches. In some embodiments, a final height H3 is produced by an expansion die during a final forming process and wherein the height is increased by the expansion die. In alternative embodiments, no significant change in height is produced by the expansion die. Rather, in such embodiments, a height of the cup is increased by the draw operations. An opening 7 is provided at the upper end of the tapered cup 20, wherein the opening is devoid of a closure, a seal, etc. The opening is at least partially defined by the circumference of the curled portion 6, and wherein the curled portion 6 comprises at least a portion of a user-interface wherein a user's mouth is intended to contact the curled portion 6 during drinking.

FIG. 5 is a cross-sectional elevation view of the tapered metallic tapered cup 20 as shown in FIG. 4 , and wherein the cross-section is taken at line 5-5 of FIG. 4 . As shown in FIG. 5 , the tapered cup 20 comprises a tapered profile comprising multiple stepped sections 10 a, 10 b, 10 c, 10 d, 10 e, wherein each successive section comprises a smaller diameter by way of a step 22. Additionally, each section comprises an angled or tapered sidewall formed by a tapered expansion die.

Various internal diameters of a plurality of sections 10 are provided. In some embodiments, a finished tapered cup 20 comprises a plurality of sections 10 comprising relative diameters characterized as: 10 a>10 b>10 c>10 d>10 e. Specific diameters are provided and illustrated as being measured from an upper portion of each respective section 10. The plurality of sections 10 comprise varying heights, wherein the relative heights can be characterized as: 10 c>10 d>10 b>10 e>10 a. An internal diameter of a curled section 6, which also comprises a drinking interface, comprises a diameter of between approximately 2.0 and 5.0 inches. Details Y and Z are indicated on FIG. 5 , and are shown in detail in FIGS. 9 and 8 , respectively. Various expansion angles are illustrated in FIG. 5 , wherein each section 10 expands outwardly along a height of the section 10. As shown, each section 10 comprises a different expansion angle (expressed as the difference between the expanded diameter and the initial diameter, divided by the initial diameter of the straight walled section). In alternative embodiments, however, it is contemplated that each section 10 comprises the same expansion angle. In the depicted embodiment, the relative expansion angles can be expressed as: 10 e>10 b>10 d>10 c. The uppermost section 10 a provided in FIG. 5 comprises a straight-walled section that is devoid of an expansion angle.

The straight wall sections of FIG. 5 are contemplated as being formed by drawing the cup and providing an expansion or increased diameter to each of the sections. In some embodiments, it is contemplated that each of the sections is formed using a draw and, subsequent to the initial formation of each of the drawn sections, one or more expansion dies are provided to expand each of the sections. In other embodiments, it is contemplated that the drawing and expanding of the straight wall sections are performed in an alternating manner wherein a first section is drawn and then expanded, a second section is then drawn and expanded, etc. It is also contemplated that the number of draw and expansion operations need not be equal. For example, multiple expansion steps may be provided on a portion formed from a single draw operation. Additionally, a section may be drawn and not provided with a corresponding expansion operation. Further, operations may be combined and draws (for example) can be performed in one step using air pistons or a draw and expand operation can be combined.

FIG. 6 is a top plan view of a finished tapered cup 20 according to the embodiment of FIG. 4 . Multiple stepped sections 10 are shown in plan view, and a bottom of the tapered cup 20 comprises a dome 24 in some embodiments.

FIG. 7 is a detailed view of two finished tapered cups 20 provided in a stacked arrangement, and wherein respective curled portions 6 of each tapered cup 20 are provided with a separation or stand-off height. A stand-off height is provided that comprises a height or distance between successive upper ends of the curled portions 6. In the depicted embodiment, the stand-off height is between approximately 0.00 inches and approximately 1.0 inches. Preferably, the stand-off height is between approximately 0.20 and 0.50 inches. The stand-off height provides a user with the ability to grasp and separate stacked cups, for example. Although various embodiments contemplate a stand-off height, such a stand-off feature is not required and alternative embodiments contemplate that such a stand-off is not provided.

FIG. 8 is a detailed cross-sectional elevation view of a finished tapered cup 20 showing the upper portion of the cup including the curl 6. FIG. 8 is a detailed view of detail Z of FIG. 5 . As shown in FIG. 8 , a curled portion 6 of the cup comprises a radius of curvature of between approximately 0.010 inches and 0.250 inches. In the depicted embodiment, a preferred radius of curvature comprises a curvature of approximately 0.040 inches. FIG. 8 also provides a step 22 between adjacent sections 10 a, 10 b of a tapered cup 20. As shown, the step comprises a first radius of curvature of approximately 0.040 inches and a second radius of approximately 0.040 inches, wherein the two radii of curvature each comprise a transition or departure from an adjacent sidewall of the sections 10 a, 10 b. Although only one step 22 is depicted in FIG. 8 , it is contemplated that each step 22 of the tapered cup 20 is provided comprising the same dimensions as the step 22 shown in FIG. 8 . The step 22 can be of any dimension or combination of one or more radii. In certain embodiments, radii between approximately 0.01 inches and 0.250 inches are provided.

FIG. 9 is a detailed cross-sectional elevation view of a finished tapered cup 20 showing the bottom portion of the tapered cup 20 comprising a dome 24. FIG. 9 is a detailed view of detail Y of FIG. 5 . FIG. 9 includes various dimensions and details of a tapered cup according to one embodiment of the present disclosure. As shown, the tapered cup 20 comprises a dome 24 in a lower portion of the preform 20. A bottom portion 10 e of the cup comprises an outer diameter of between approximately 1.50 and 3.50 inches. A radius of curvature R2 is provided as a transition between the bottom section 10 e and the dome, wherein the radius of curvature R2 comprises a radius of between approximately 0.010 inches and approximately 0.250 inches. Preferably, the radius of curvature is approximately 0.10 inches. A flat standing surface 30 is provided between the radius R2 and the dome 24, wherein the flat surface 30 comprises a resting or supporting for the finished preform 20. The flat surface 30 generally comprises an annular surface with a width of between approximately 0.0010 inches and 0.125 inches, and preferably of approximately 0.084 inches. In some embodiments, it is contemplated that a flat surface extends around only a portion of a diameter or circumference of a cup. The flat surface 30 extends into a domed section 24 comprising multiple radii of curvature. A central portion of the domed feature 24 comprises a radius of approximately 15.0 inches, and the domed portion 24 transitions to a flat surface 30 as shown. The domed portion 24 and the dimensions thereof may vary in dimensions. In further embodiments, a flat standing surface is not provided.

As shown in FIG. 9 , a bottom section 10 e of the cup comprises a gauge or wall thickness of approximately 0.0090 inches, and an adjacent section 10 d, comprises a gauge or wall thickness of approximately 0.0040 inches. Thin walled cups are contemplated as comprising a thickness of between approximately 0.0060 inches and 0.0035 inches. The bottom section 10 e comprises a section of enhances gauge and therefore comprises enhanced durability as the bottom section 10 e is intended to contact another surface, such as when the cup is placed on a surface, dropped, etc. In certain embodiments, the cup comprises a single metal thickness.

FIG. 10 is a flow chart depicting a method of forming a metal cup according to one embodiment of the present disclosure. As shown, the method of FIG. 10 comprises a first step 50 of providing a coil of metal material from which a cup is to be formed. Preferably, the coil provided in step 50 comprises a coil of aluminum stock material. A second step 52 is provided wherein at least one cup is formed from a blank cut from the coil. The cup is preferably formed using a blank and draw operation. Subsequently, a redraw step 54 is provided wherein the cup is subjected to at least one redraw operation. Method steps 50, 52 and 54 provide an initial cup that is ready for further processing according to methods of the methods of the present disclosure.

The cup provided from the redraw step 54 is further subjected to forming and finishing steps as shown and described herein. In the depicted embodiment of FIG. 10 , the cup is subjected to a trimming operation wherein an upper, open end of the cup is cut or trimmed to remove material at step 58. Subsequently, at step 60, the upper trimmed end of the cup is provided with at least one curl (see 6 of FIG. 2 , for example). Subsequently, and referring now to step 62, at least one stepped draw operation is performed wherein multiple straight-wall sections are formed in the cup (see FIG. 3 , for example). The cup is then expanded via at least one expansion operation in step 64. In some embodiments, the expansion step 64 comprises expanding each of the straight wall sections to a larger diameter using one or more dies with a tapered profile. A doming operation 66 is then performed to provide a dome in a bottom portion of the cup. The dome is probably provided to enhance the structural integrity and stability of the cup. The series of steps described herein and referenced as sequence 56 comprise steps that are contemplated as being re-ordered or eliminated depending on design, customer requirement, and/or machine technology. While at least one embodiment contemplates performing the steps as illustrated in FIG. 10 , it is also contemplated that one or more of the steps indicated by 56 may be eliminated or re-sequenced.

Subsequent to the sequence illustrated as 56 in FIG. 10 , the cup is then subjected to a washing step 68. After washing, the cup is decorated at step 70, provided with a bottom coat at step 72, and/or an internal coating (“IC”) spray step 74. The plurality of method steps indicated by 76 in FIG. 10 are contemplated as being re-ordered or eliminated depending on design, customer requirement, and/or machine technology. For example, depending on customer needs and requirement, the method may terminate after a decoration step 70.

FIG. 11 is a flow chart depicting a method of forming a metal cup according to another embodiment of the present disclosure. As shown, an initial step 80 is provided wherein a coated coil is provided in the form of stock material. Preferably, the coil in step 80 comprises coated aluminum. However, various embodiments of the present disclosure provide and contemplate a “coated” coil that comprises an epoxy, film, polymer or other “paint” cured, laminated or extruded to a surface of the metal using various methods. At least one cup is formed from the coil at step 82, the cup being formed from a blank sheet of material cut from the coil and a draw die. The initial cup formed in step 82 is then subjected to at least one redraw operation in step 84. Having formed an initial cup, the process advances to step 88 where an upper, open portion of the cup is trimmed in step 88, subsequently provided with a curl at step 90, subjected to a stepped redraw operation at step 92 to form at least one straight-walled portion, expanded in diameter at step 94, and provided with a bottom dome through a doming operation at step 96. Steps 88-96 of FIG. 11 are collectively referred to as sequence 86. The steps of this sequence 86 are contemplated as being re-ordered or eliminated depending on design, customer requirements, and/or machinery.

Subsequent to the method steps of the depicted sequence 86, the cup is then subjected to a rinsing or washing operation 100 and a decorating step 102. In FIG. 11 , washing and decorating are depicted as a final sequence 98 in which the cup is finished. It is also contemplated, however, that the sequence 98 can be provided subsequent to the redraw step 84 and prior to sequence 86.

FIG. 12 is a flow chart depicting a method of forming a metal cup according to another embodiment of the present disclosure. As shown in FIG. 12 , a plurality of initial cup forming steps are provided wherein a coil 104 is provided. At least one cup is formed from the coil material at step 106, preferably by a blank and draw operation. A redraw step 108 is provided in some embodiments to further form the cup. A bodymaker at step 110 is optionally used to form the final cup height and/or iron the walls to a final thickness.

An upper portion of the cup is then trimmed at step 112. The trimmed cup is then preferably subjected to a washing operation 114. A decorating and/or coating sequence 116 is provided subsequent to washing, the decorating sequence comprising the steps of decorating the cup at step 118, providing a bottom coat 120, and/or providing an internal coating to the cup at step 122. One or more of the steps of the coating sequence 116 may be reordered, eliminated, and/or moved after a rinsing step 132.

Preferably subsequent to the coating sequence 116, final forming steps 124 are provided. The final forming steps preferably comprise at least one of providing a curl to the trimmed portion of the cup at step 126, performing at least one stepped draw operation 128 to form one or more straight walled section in the cup, and performing an expansion step 130 to expand the diameter of the straight walled section(s). The final forming steps 124 are contemplated as being reordered or eliminated depending on user requirements. A rinsing step 132 is provided as a finishing step. However, as previously noted, one or more steps of the coating sequence 116 may be re-ordered such that they occur subsequent to the rinsing step 132. The embodiment of FIG. 12 contemplates providing a dome in a bottom portion of the cup. A doming operation 134 is provided and is contemplated as occurring during the bodymaker operation 110 or prior to rinsing as a final, separate operation.

FIG. 13 is a flow chart depicting a method of forming a metal cup according to another embodiment of the present disclosure. As shown in FIG. 13 , a cup is provided at step 140 and is preferably formed from a coil of blank aluminum. The cup is then redrawn at step 142, wherein the cup is subjected to one or more redraw operations. The cup is then fed to a bodymaker at step 144 to form a final cup height and diameter and form a final wall thickness via ironing. Subsequently, the cup is trimmed at step 146 wherein an excess cup height created from the redrawing and/or bodymaker operation is trimmed. A cleaning and decorating sequence 150 is provided wherein the cup is subjected to at least one of a rinsing step at 152 and a decorating step 154. The steps of the cleaning and decorating sequence 150 may be moved after the expansion 162 or doming step 164 provided in FIG. 13 . One of ordinary skill in the art will recognize that various cleaning and decorating steps may be conducted at different points in the manufacturing process. The present disclosure provides certain method steps and orders of operations for illustrative purposes, and various alternatives are contemplated.

The cup is then advanced to finishing sequence 156, wherein the finishing sequence comprises providing a curl to the trimmed portion of the cup at step 158, providing a stepped redraw operation 160, providing an expansion operation 162 and providing a dome in a bottom portion of the cup at step 164. although the doming step 164 is contemplated as occurring a final step in the embodiment of FIG. 13 , it is also contemplated that the doming step may occur within the bodymaker at step 144, making the expansion operation 162 the final step of the embodiment of FIG. 13 . The steps of the finishing sequence 156 of FIG. 13 may be re-ordered or eliminated depending on design, customer requirement, and/or machine technology.

FIG. 14 is a flow chart depicting a method of forming a metal cup according to another embodiment of the present disclosure. As shown in FIG. 14 , a cup is provided from a slug of blank material. As shown, an initial step 170 comprising providing a slug of material (e.g. aluminum). The slug is impact extruded at step 172 to form a cup. An upper end of the cup is trimmed to a preferred height at step 174 and subsequently brushed and washed at step 176 and 178, respectively. In some embodiments, a step of ironing the impact-extruded cup is provided after impact extrusion (step 172) and prior to trimming (step 174). A washed cup 178 is then provided and subjected to a coating and decorating sequence 180 as shown. The coating and decorating sequence 180 of FIG. 14 comprises the steps of decorating the cup 182, providing a bottom coat to the cup 184 and providing an internal coating (e.g. sprayed coating) to the cup 186. The steps of the coating and decorating sequence 180 may be reordered and/or may be provided subsequent to the rinsing step 198.

After the coating and decorating sequence 180, the method of FIG. 14 proceeds to a finishing sequence 188 that comprises the steps of curling an upper, trimmed portion of the cup at step 190, performing a stepped draw operation 192, providing an expansion operation using one or more expansion dies 194 and forming a dome 196 in a bottom portion of the cup. The steps of the finishing sequence may be re-ordered or eliminated depending on user preference, design, customer requirements, and/or available machine technology. Subsequent to the finishing sequence 188, the cup is washed and/or rinsed at step 198.

FIGS. 15A-15B depict a cup according to one embodiment of the present disclosure. As shown, the cup 200 comprises a rotationally-symmetrical profile with a plurality of steps or ribs 202. In the embodiment of FIGS. 15A-15B, the cup 200 does not comprise an anti-sticking feature according to other embodiments of the present disclosure. Accordingly, a plurality of cups of the embodiment of FIGS. 15A-15B are capable of being stacked or nested in a compact manner. However, this compact manner including a close contact and nesting between an exterior of a sidewall 204 of the bottom portion of one cup and an interior of a sidewall 204 of a second, adjacent cup can cause adjacent cups to be difficult to separate due to a friction force and/or vacuum force between the two cups. FIG. 15B is a detailed view of the lower portion of the cup of the embodiment of FIG. 15A.

FIGS. 16A-16B depict a container 210 according to one embodiment of the present disclosure that comprises a bottom portion 212 having a specific shape and structure to render the separation of stacked, adjacent cups easier for a user. FIG. 16A is an elevation view of the container 210, which comprises a plurality of tapered sections 214 separated by steps or ribs 216. The bottom portion 212 comprises an angled or tapered portion and a base.

FIG. 16B is a cross-sectional elevation view of the container 210 of FIG. 16A. More specifically, the bottom section 212 of the container 210 is enlarged for clarity. As shown, the bottom section 212 comprises a domed portion 226 surrounded by a first radius 224. An inwardly-tapered sidewall 218 extends upwardly to a second radius 220, with a third radius 222 connecting the second radius 220 and a tapered section 214. In some embodiments, a straight-walled section is provided between the second and third radii. As shown in FIG. 16B, the first and third radii 224, 222 comprise convex bends, and the second radius 220 comprises a concave bend. Additionally, the inwardly-tapered sidewall 218 comprises a slope or angle that extends inwardly (i.e. toward a central longitudinal axis of the container from bottom to top), as opposed to the tapered sections 214 that comprise an outward slope or angle. Although a straight walled section 218 is shown in FIG. 16B, other embodiments of the present disclosure contemplate that the first radius 224 extends directly into the second radius 220. Various embodiments of the present disclosure contemplate that the second radius 220 is provided closer to a centerline of the cup than the first radius 224 to provide the stand-off feature shown and described herein. The cup comprises multiple inflection points, wherein the dome transitions to a first radius 224, the sidewall 218 transitions to the second radius 220, and the second radius transitions to the third radius 222.

In various embodiments, the first radius 224 comprises a radius of between approximately 0.050 inches and 0.20 inches, and preferably of about 0.100 inches. In various embodiments, the second radius 220 comprises a radius of between approximately 0.050 inches and 0.20 inches, and preferably of about 0.100 inches. In various embodiments, the third radius 222 comprises a radius of between approximately 0.030 inches and 0.20 inches.

In various embodiments, including but not limited to the embodiment shown in FIGS. 16A-16B, a convex curvature of the third radius 222 comprises a radius of curvature of between approximately 0.020 inches and 0.060 inches and preferably of about 0.050 inches. A concave curvature of the second radius 220 comprises a radius of curvature of between approximately 0.050 inches and 1.50 inches and preferably of about 0.080 inches or 0.100 inches. A substantially horizontally-oriented straight walled section is provided between the second radius 220 and the third radius 222.

FIG. 17 is a cross-sectional elevation view of a plurality of containers 210 a, 210 b provided in a stacked arrangement. As shown, the containers 210 a, 210 b are of similar construction and size and each comprise an anti-sticking feature as shown and described herein (see FIGS. 16A-16B, for example). The first radius 224 a of a first cup 210 a is provided on the interior of the second radius 220 b of the second cup 210 b. The third radius 222 b of the second cup 210 b extends outwardly away from the first cup 210 a and a void space 230 is created between the two cups 210 a, 210 b. The void space 230 is provided between the inwardly-tapered portion 218 of the first cup 210 a and the outwardly tapered portion 214 of the second cup 210 b. Additionally, the structure of the lower portions of the cups 210 a, 210 b provides for a spacing or stand-off height 225 at the upper ends of the cups wherein the respective curls provided at the upper ends of each of the cups are spaced apart. This allows for a user to grasp and easily separate nested or stacked cups. Certain panels (e.g. the tapered portion 214) preferably do not contact one another. Friction is thereby reduced and vacuum suction is avoided, thus allowing for easier separation of adjacent cups.

FIGS. 18-19 are cross-sectional elevation views of forming tools in accordance with one embodiment of the present disclosure. As shown, a tool pack 250 is provided that comprises a die center punch 252 with a void 253 for receiving a domed bottom portion of a cup. The tooling 250 also comprises a redraw pressure pad 254, a redraw die 256, and a reforming tool 260. A metal cup 262 is shown relative to the forming tools. The redraw die 256 comprises a venting feature 258 to allow air to escape the tool during a forming operation.

FIG. 18 shows the tooling 250 in an initial or starting position of an operation for forming an anti-sticking feature of a cup. As shown in FIG. 18 , the cup 262 comprises a tiered or stepped profile, but has not yet been provided with an anti-sticking feature of the present disclosure. The pressure pad 254 and redraw die 256 have been brought into contact and the cup 262 is compressed between the two components. An internal gap 264 is provided to allow for the bottom portion of the cup 262 to move outwardly.

FIG. 19 shows the forming tools 250 and the cup 262 in a forming position. As shown in FIG. 19 , the bottom portion of the cup 262 has been provided with an anti-sticking feature. During formation, the reforming tool 260 is moved downwardly (at least as shown in FIG. 19 ) to contact the bottom portion of the cup 262. A concave void 266 provided in the reforming tool 260 that contacts the bottom portion of the cup 262 exterior to a domed area of the cup 262 and expands the bottom portion. The result is that the cup takes on a shape as shown in FIG. 19 wherein a lowermost portion of the cup 262 is expanded outwardly relative to the remainder of the bottom portion and the cup 262 is provided with an inward taper as is further shown and described in FIG. 16B, for example. The metal of the cup moves outwardly at a bottom portion (corresponding to the first radius 224 of FIG. 16B), and inwardly proximal to the second radius (220 in FIG. 16B). During this movement, dome home is preferred kept constant.

FIG. 20 is a cross-sectional elevation view of cups 300 a, 300 b provided in a stacked or stacking arrangement. As shown, first and second cups 300 a, 300 b each comprise an upper portion with a peripheral curl 302 a, 302 b and lower portion having an upstanding dome portion 304 a, 304 b. A cup height extends between the upper portion and lower portion of each cup, and a plurality of cup sections or panels 308, 310, 312, 314, 316, 318 are provided along the height. The panels are shown and labeled with respect to the second cup 300 b for purposes of clarity. It will be recognized, however, that the two cups of FIG. comprise substantially the same layout and geometry. The cup shape including number of panels and size of panels may vary. In preferred embodiments, each cup comprises a plurality of panels wherein the panels sequentially decrease in diameter from top-to-bottom to form the tapered profile shown in FIG. 20 , for example. As shown in FIG. 20 , it is an object of the present disclosure to provide an offset and/or prevent contact between bottom portions of each cup to reduce a removal force required to extract the first cup 300 a from within the second cup 300 b. In the embodiment of FIG. 20 , this offset is accomplished by the provision of outwardly oriented projection 306. The projection 306 of FIG. 20 comprises an annular or semi-annular projection or protrusion provided at an intersection of adjacent cup panels 316, 318. The projection 306 a of the first cup 300 a is sized and operable to contact an upper portion 302 b of the second cup 300 b in FIG. 20 . As shown, the projection 306 a creates a limit to the extent to which the first cup 300 a is allowed to extend into or next into the second cup 300 b. As shown in FIG. 20 , the projection 306 prevents contact between certain portions of the cups. For example, in the embodiment of FIG. 20 , contact between the domed portions 304 a, 304 b is prevented as is contact between various panels of each cup 300 a, 300 b. Gaps are provided at various locations along the height of the cup, thereby reducing friction between the cups and reducing the required pull-out or removal force. A gap 320 is shown between an upper portion of a first panel 308 of the second cup 300 b and a lower portion of the first cup 300 a. In certain embodiments, a second contact point is provided at this location (320 in FIG. 20 ). The contact may be achieved by, for example, extending the height of the first panel 308 and/or reducing a height of an uppermost panel 318. Thus, in certain embodiments, two contact points are provided between two adjacent cups and gaps are preferably maintained between panels of the cups.

FIG. 21 is a detailed cross-sectional elevation view of a portion of a cup 300 according to the embodiment of FIG. 20 . As shown, an upper end of the cup comprises a curl 302 a with an uppermost panel 318 extending therefrom. The uppermost panel 318 is depicted as a vertical panel in FIG. 21 , although alternative wall angles are contemplated. The uppermost panel 318 transitions into an outward projection 306 a which is contemplated as comprising a semiannular projection. In preferred embodiments, the semiannular projection 306 a extends 360 degrees around the cup. In alternative embodiments, the projection extends along one or more portions of a cup's circumference and is not a continuous feature or a single projection. Although various embodiments of the present disclosure contemplate a semiannular projection, alternatively shaped projections are contemplated. For example, projections with triangular cross-sections and various other shaped projections are contemplated that achieve the goals and objections of the present disclosure. The projection 306 a transitions into an adjacent panel 316. Various additional panels are contemplated as being provided (see FIG. 20 ). It is contemplated that projections in various forms and shapes, including dimples and circular projections are provided and may be formed by an outward force or impact during manufacturing. In some embodiments, one or more vertically extending projections are provided on an interior or exterior of a cup to provide contact with an adjacent cup and achieve an offset. While various embodiments of the present disclosure contemplate forming a projection as part of the cup forming process, alternative embodiments contemplate adding a projection or similar feature as a separate process. For example, in some embodiments, a projection, bead, or spot-weld feature is provided on a cup after the cup is at least partially formed from a stock material.

Referring again to FIG. 21 , the projection 306 provides a first outer diameter D1 of the cup as defined by either a continuous projection or between two opposing projections. The uppermost panel 318 comprises an internal diameter D2 defining a panel or cup section of the largest internal diameter. In various embodiments, the internal diameter D2 comprises a diameter of between approximately 1.0 and approximately 5.0 inches. More preferably, D2 comprises a diameter of between 2.0 and 4.0 inches. In various embodiments, cups are provided with an internal diameter D2 that varies based on cup size. For example, an internal diameter D2 of between 3.610 and 3.625 inches is provided for 16, 20 and 24 ounce cups; an internal diameter D2 of between 2.850 and 2.865 inches is provided for 9 and 12 ounce cups. Such dimensions are provided to illustrate certain contemplated embodiments. Alternative embodiments and proportions are contemplated, and no limitation with respect to cup size and diameter is provided. In preferred embodiments, the first diameter D1 is greater than the second diameter D2 and provides a contact point or resting surface for the cup. In some embodiments, the first diameter is between 1.001 times larger and 1.2 times larger than the second diameter. Accordingly, in various embodiments, an outer diameter D1 formed by the projection 306 is between approximately 3.628 inches and 4.35 inches (for 16, 20 and 24 ounce cups, for example) and between approximately 2.002 and 2.40 inches for smaller cup sizes. In some embodiment, 9 and 12 ounce cups are provided with outer diameters D1 of approximately 2.869 inches and 3.438 inches, respectively.

The projection comprises a radius R1 that is preferably between approximately 0.0010 inches and 3.0 inches and preferably about 0.005 inches. In preferred embodiments, the projection comprises a single, constant radius. In alternative embodiments, one or more projections are provided that comprise multiple radii of curvature and/or linear portions, such as protrusions of triangular cross-sections and various other shapes of projections.

FIG. 22 is a cross-sectional elevation view of cups 400 a, 400 b provided in a stacked or stacking arrangement. As shown, first and second cups 400 a, 400 b each comprise an upper portion with a peripheral curl 402 a, 402 b and lower portion having an upstanding dome portion 404 a, 404 b. A cup height extends between the upper portion and lower portion of each cup, and a plurality of cup sections or panels 408, 410, 412, 414, 416, 418 are provided along the height. The panels are shown and labeled with respect to the second cup 400 b in the interest of clarity. It will be recognized, however, that the two cups of FIG. 22 comprise substantially the same layout and geometry. The cup shape including number of panels and size of panels may vary. In preferred embodiments, each cup comprises a plurality of panels wherein the panels sequentially decrease in diameter from top-to-bottom to form the tapered profile shown in FIG. 22 , for example. As shown in FIG. 22 , it is an object of the present disclosure to provide an offset and/or prevent contact between bottom portions of each cup to reduce a removal force required to extract the first cup 400 a from within the second cup 400 b. In the embodiment of FIG. 22 , this offset is accomplished by the provision of inwardly oriented projection 406. The projection 406 of FIG. 22 comprises an annular or semi-annular projection or protrusion provided at an intersection or transition of the peripheral curl 402 and the uppermost panel 418. The projection 406 a is sized and operable to contact an exterior of an adjacent cup. More specifically, and as shown in FIG. 22 , the projection 406 b of the second cup extends inwardly toward a centerline of the cup 413 and is operable to contact a lower portion of the uppermost panel 418 of the first cup. As shown, the projection 406 creates a limit to the extent to which the first cup 400 a is allowed to extend into or nest into the second cup 400 b. As shown in FIG. 22 , the projection 406 prevents contact between the cups. For example, in the embodiment of FIG. 22 , contact between the domed portions is prevented as is contact between the panels of each cup 400 a, 400 b. Gaps are provided at various locations along the height of the cup, thereby reducing friction between the cups and reducing the required pull-out or removal force. A gap 420 is shown between an upper portion of a first panel 408 of the second cup 400 b and a lower portion of the first cup 400 a. In certain embodiments, a second contact point is provided at this location (420 in FIG. 22 ). The contact may be achieved by, for example, extending the height of the first panel 408 and/or reducing a height of various panels (e.g. panel 418 in FIG. 22 ). Thus, in certain embodiments, at least two contact points are provided between two adjacent cups and gaps are preferably maintained between panels of the cups. The gaps reduce a frictional force provided between the cups and, in some embodiments, reduce a vacuum or suction force between the cups and allow for easier separation and removal of cups from a stacked arrangement.

FIG. 23 is a detailed cross-sectional elevation view of a portion of a cup 400 according to the embodiment of FIG. 22 . As shown, an upper end of the cup comprises a curl 402 a with an uppermost panel 418 extending therefrom. The uppermost panel 418 is depicted as a vertical panel in FIG. 23 , although alternative wall angles are contemplated. A projection 406 a is provided at a transition between the curl 402 a and the uppermost panel 418. The projection 406 a comprises an inward projection which is contemplated as comprising a semiannular projection. In preferred embodiments, the projection 406 a extends 360 degrees around the cup. In alternative embodiments, the projection extends along one or more portions of a cup's circumference and is not a continuous feature or a single projection. In additional, projections may comprise various cross-sectional shapes and exterior appearances. As used herein, the term “semiannular” refers to the cross-sectional shape of the projection, which is a partial circle extruded around a point of rotation. The extrusion and projection may comprise a 360 degree projection, or some circumference less than 360 degrees. The projection 406 a transitions into the uppermost panel 418. Various panels are contemplated as being provided (see FIG. 22 ). The cup comprises a first internal diameter D3 defined by the inner surface of the inward projection 402 a. In some embodiments, discrete inward projections are provided that do not extend around the entire cup circumference. A second internal diameter D4 is provided which is larger than the first internal diameter D3 and wherein the second internal diameter D4 comprises an internal diameter of a cup section formed by the uppermost panel 418.

As discussed, the projection 406 a can be continuous around the entire circumference of the cup or can be broken into any number of smaller discontinuous features around the circumference. For the purposes of FIG. 23 , D3 is considered as a diameter between a continuous, 360 degree projection or as a distance between opposing projections positioned approximately 180 degrees apart. The first internal diameter D3 of FIG. 23 comprises a diameter that is at least partially defined by the projection 406 a. The projection 406 a comprises a radius of curvature R2. The radius of curvature is contemplated as comprising a radius of between approximately 0.001 inches and approximately 3.0 inches. The radius is preferably continuous, but projections having varying radii of curvature are also contemplated.

In various embodiments, the first internal diameter D3 comprises a constriction at or near the top of the cup 400 that is between approximately 0.8 times the second internal diameter D4 and approximately 0.999 times the second internal diameter D4. Accordingly, the first internal diameter D3 is contemplated as being a function of the second internal diameter D4. For certain cups (e.g. 16, 20 and 24 ounce volume cups), the second internal diameter D4 comprises a diameter of approximately 3.625 inches, and the first internal diameter D3 formed by the projection is between approximately 2.90 and 3.621 inches. For smaller cups comprising a second internal diameter D4 of 2.0 inches, the first internal diameter D3 formed by the projection is between approximately 1.6 and 1.999 inches. In various embodiments, it is contemplated that the first internal diameter D3 is between approximately 1.0 and 5.0 inches. However, as discussed herein, the first internal diameter D3 is preferably a function of related cup feature geometries. Various dimensions provided with respect to FIG. 23 and other Figures and embodiments are provided for illustrative purposes only. Various different dimensions and proportions are contemplated as being within the scope of various inventive features of the present disclosure. No limitation with respect to dimensions or proportions is provided.

While projections of the present disclosure have been illustrated as being provided in certain locations including, for example, a lower, outer region of an uppermost panel (306 a in FIG. 20 ) and an inner region of a peripheral curl (406 a in FIG. 22 ), it will be recognized that the present disclosure is not limited to cups having projections in these specific locations. As shown and described herein, cups without projections are contemplated. Additionally, projections provided at alternative locations are contemplated. For example, some embodiments of the present disclosure contemplate providing an outward projection a point along a height of an uppermost panel (e.g. anywhere along the height of panel 318 in FIG. 20 ) which is brought to rest on a curl of a cup in which the first cup is nested. In additional embodiments, an inward projection is contemplated as being provided on an upper panel and below the peripheral curl. No limitation with respect to the specific or relative positioning of projections is provided. Projections at different locations on one or more panels may be formed, for example, by fly spinning techniques and similar processes.

Projections as shown and described herein are also contemplated as being provided on various different panels. For example, a projection may be provided on an upper portion of panel 412 of FIG. 22 that creates the offset(s) and gap(s) as shown and described herein.

In various embodiments, methods of forming cups are provided. In some embodiments, at least one projection is formed in a cup to provide a contact or resting point and wherein the projection is formed during a first expansion operation of the cup. The projection is formed by pushing on a rib or transition between cup sections (e.g. the transition between the uppermost panel and an adjacent panel. In further embodiments, it is contemplated that projections of the present disclosure are formed with an independent press that pushes on a rib or transition while retaining the rest of the cup. It is further contemplated that a rotary action is provided to pushes rollers into the rib or transition in a manner similar to the action of a spinner or dome reformer tool. For example, circumferential grooves or features are contemplated as being created by spinning rollers around an outer diameter of a cup with force pushing inwardly to create a bump or feature. It is also contemplated a tool is inserted into a cup and material is spun outwardly to form features. It is further contemplated that a reverse taper operation is provided wherein the curl of a cup is held and a punch is used to push on the rib or transition on or proximal to which a projection is to be formed, and the rib is pushed against a die with springs thus forcing the rib outwards. Additionally, an expansion tool is contemplated as being provided that squeezes past the curl and expands an uppermost panel to form a projection. It is also contemplated that a cam activated tool is provided that pushes multiple discontinuous bumps into a rib.

Inwardly extension projections provided adjacent to curl, such as those shown in FIGS. 22-23 , for example, are contemplated as being formed by one or more processes. For example, a tool is contemplated as being provided in the curling die that allows for a section of the curl to move or “bump” inwardly. Additionally, a cam activated tool is contemplated that flattens or “smashes” the curl. Further, it is contemplated that a set of tooling is provided that retains the curl and pulls on the base of a cup, thereby unravelling or partially unravelling the curl. Further, it is contemplated that a reverse taper operation is provided wherein the curl is allowed to move inwardly and the rib or transition between panel is retained in place.

FIG. 24 is a cross-sectional elevation view of a container according to one embodiment of the present disclosure. As shown, the container 500 comprises varying wall thicknesses or gauges throughout the body of the container. Dimensions are provided in FIG. 24 , but it should be recognized that the dimensions are provided as examples and no limitation with respect to dimensions are provided. For example, a thickness or gauge in the base 502 of the container is approximately 0.0096 inches and a thickness or gauge at or proximal to an upper portion 504 of the container is approximately 0.006 inches. A transition or “rework taper” 506 is provided wherein the thickness transitions from the base 502 to the upper portion 504. The rework taper 506 comprises a varying or tapered thickness wherein the gauge is approximately 0.0096 at an intersection of the base 502 and the rework taper 506, is approximately 0.006 at a transition between the rework taper 506 and the upper portion 504. The thickness of the rework taper 506 preferably gradually transitions along the height of the rework taper portion 506. In some embodiments, the thickness or gauge is constant along the thin wall upper portion 504. In other embodiments, the gauge continues to taper or decrease along the height of the cup until it gradually reaches a minimum thickness. Although the container of FIG. 24 comprises vertical sidewalls, it will be recognized that a tapered profile (see FIG. 25 , for example) is also contemplated. Cups and containers are contemplated as comprising a rework taper, regardless of the final shape of the container.

FIG. 25 is an elevation view of a container according to one embodiment of the present disclosure. As shown in FIG. 25 , a bottom portion of the container 6 comprises a dome. The dome comprises a gauge T_(d). A lowermost panel 10 e and/or an adjacent panel 10 d are contemplated as comprising a variable thickness and rework taper as shown and described with respect to FIG. 24 that reduces to or approaches a limit corresponding to a thinwall thickness T_(tw), that is less than the dome of the gauge T_(d). It is contemplated that some panels comprise a thickness that is substantially equivalent to an incoming or initial gauge. Panel 10 e, for example, is contemplated as comprising a thickness that is equal to the incoming or original gauge as it is formed from parts of the dome (502 in FIG. 24 ). A remainder of the container (i.e. areas above section 10 d) are provided with a substantially consistent thinwall thickness T_(tw). An uppermost panel 10 a and the curl are provided with a thickwall thickness T_(k) to provide structural support and stability. A transition from the thinwall thickness T_(tw) to the thickwall thickness T_(k) is contemplated as being provided in one of the upper panels 10 a, 10 b. It is contemplated that the thickwall T_(k) gauge is greater than the thinwall gauge T_(tw) and less than the dome gauge (i.e. T_(tw)<T_(k)<T_(d)).

In various embodiments of the present disclosure, cups sections 10 a, 10 b, 10 c, 10 d, 10 e comprise various gauges or wall thicknesses. Thickness may vary and be selected to save material costs, increase or decrease strength in certain regions of the cup, and provide for preferred user-interfaces and ergonomic feel. In some embodiments, for example, each section comprises its own thickness. The thicknesses do not necessarily decrease from the bottom of the cup to the upper portions. Any number of combinations of thicknesses or gauges are contemplated. For example, section 10 d may be thicker than section 10 c and section 10 b may also be thicker than section 10 c. Additionally, containers of the present disclosure are contemplated as comprising multi-section cups and single panel cups. Regardless of the number of steps or sections, it is contemplated that the containers comprise either linear or non-linear changes in gauge or thickness.

FIG. 26A is a perspective view of a punch 520 for forming containers of the present disclosure. The punch 520 comprises a thinwall portion 521 and a thickwall portion 523 for forming containers according to various embodiments of the present disclosure. As shown in FIG. 26B, the punch 520 comprises a transition step 522 wherein a diameter of the punch is reduced from a first diameter D1 to a second diameter D2. As shown in FIG. 26C, the transition step 522 is provided in a central region of the punch 520. In the depicted embodiment, the first diameter D1 is between approximately 0.00010 and 0.0050 inches greater than the second diameter D2. In preferred embodiments, the transition between the first diameter D1 and the second diameter D2 is preferably between approximately 0.0010 and 0.0030 inches (e.g. 0.002200 inches). A rework taper portion 524 is shown in FIG. 26C at one end of the punch 520. As shown in FIG. 26B, the transition step 522 comprises a length of between approximately 0.050 and 1.00 inches and more preferably of between 0.100 and 0.400 inches. In some embodiments, the transition step comprises a length of approximately 0.250 inches.

FIG. 27A is a cross-sectional view of a single panel cup 600 according to one embodiment of the present disclosure. Single panel cups of the present disclosure including that shown in FIG. 27A are contemplated as comprising a domed bottom in certain embodiments. In further embodiments, single panel cups are provided comprising flat bottoms. Single panel cups of the present disclosure are contemplated as comprising a single wall with a taper or angle θ of between approximately 1.25 and 25.0 degrees. While certain embodiments of the present disclosure comprise a single panel cup with a sidewall 602 extending directly to a curl 604 (FIG. 27A, for example), further embodiments comprise a single panel cup 606 (FIG. 27B, for example) with an angled wall extending to a vertical wall 608 and the vertical wall extends to a curl 610.

Single panel cups of the present disclosure are contemplated as being formed by various processes and techniques. For example, in some embodiments, single panel cups are formed by impact extrusion, spin forming, and/or other processes. In one embodiment, a straight-walled, single panel cup is formed in a blank and draw cupper also known as a “deep draw” process. The container is then expanded. The expansion step can expand the entire length of the cup or can leave a partial straight-wall section (FIG. 27B, for example). In some embodiments, at least one of a curl, lug(s), edge treatment and/or finish is applied before or after the expansion step. Curls at an upper end of the cups are contemplated as being large enough to take up earing and eliminate the need for trimming or other treatment of the upper lip of the cup. Washing, rinsing, decorating, coating and similar treatments are contemplated as being provided at various points after the cupper process. A dome is contemplated as being provided or formed at various points in the process as well.

FIG. 28 is a plurality of process steps and processes for cup and container formation. As shown, an embodiment of the present disclosure contemplates a process 700 wherein a coil (e.g. aluminum coil) is provided. A cup is initially formed by a blank and draw operation 706. In certain embodiments (700 and 704 of FIG. 28 , for example) the cup is then expanded 708 to provide at least one tapered sidewall. In one embodiment 700, an upper lip or edge of the cup is then provided with a curl and/or edge treatment 710. A second embodiment 702 is contemplated wherein a coil is provided and a blank and draw operation 706 is performed. The upper edge or lip is then provided with a curl or edge treatment step 710. The cup is subsequently expanded 708 to provide at least one tapered sidewall. A third embodiment 704 is contemplated wherein a coil is provided, a cup is initially formed by a blank and draw process 706. The cup is then expanded and tapered 708, a trim operation is performed 712 and a curl and/or edge treatment is provided 710. As shown in the embodiments of FIG. 28 , containers of the present disclosure are contemplated as being formed with various process steps and these process may be altered in terms of their sequence and/or omitted.

As shown in FIG. 28 , embodiments and methods of the present disclosure further contemplate the provision of a dome creation step 720 and/or a wash, decoration and spray cycle 722 provided at various steps in the process. Multiple doming steps 720 and washing and decorating steps 722 are shown in FIG. 28 . It should be recognized that fewer than all of these steps are contemplated as being provided in a single cup forming process. Rather, these steps are shown as optional steps which may occur at any of the indicated positions in the sequences of FIG. 28 .

FIG. 29 depicts a container formation process according to an embodiment of the present disclosure. As shown, a process is provide and illustrated in FIG. 29 wherein a coil 800 is first provided and a blank and draw operation is performed to form an initial cup shape 802. A trim operation 804 is provided on the initial cup form and a curl or other edge treatment 806 is provided subsequent to the trim operation. The container is then expanded 808. One or more of washing, decorating, bottom coating, and IC spray operations are provided at step 810. Step 810 is contemplated as one or more finishing steps to complete a final product. As shown, a dome creation step 812 is contemplated as being performed prior to trim, after trim, after the edge treatment or after the expansion step. A decoration step is contemplated as being provided after initial cup formation 802, after the trim operation 804, and/or after the edge treatment step 806. A rinse an inspection step is further contemplated as being provided as a final step just prior to packaging for shipping.

FIG. 30 depicts three different formation methods for tapered cups of the present disclosure. The methods of FIG. 30 are contemplated as providing single panel tapered cups as shown and described herein. As shown, first 900, second 902 and third 903 processes contemplate the provision of a coil or raw material (e.g. aluminum).

A first process 900 contemplates the formation of a single panel cup by providing a coil and performing a blank and draw operation 904 on a portion of material from the coil to form an initial cup shape. One or more redraw operations 906 are provided on the initial cup shape. An expansion step 908 occurs after redraw(s) and prior to a curl or edge treatment 910. A doming operation 912 may occur at various stages including after the blank and draw step(s) 904, after the redraw step 906, after the expansion step 908, or after the edge treatment step 910. A wash, decoration, and/or coating step 916 is contemplated as being provided after the redraw step 906 and/or after the expansion step 908.

A second process 902 is contemplated and shown. The second process contemplates and provides that a curl or edge treatment step 910 is provided after a redraw step 906 and prior to the expansion step 908. A doming operation 912 may occur at various stages including after the blank and draw step(s) 904, after the redraw step 906, after the expansion step 908, or after the edge treatment step. A wash, decoration, and/or coating step 916 is contemplated as being provided after redraw step 906 and/or after curl step 910

A third process 903 is contemplated and shown in FIG. 30 . As shown, a coil or quantity of stock material is formed into an initial container shape by a blank and draw operation 904. At least one redraw operation 906 is provided and the cup is expanded at step 908. A trim step 914 is provided, and a curl edge treatment 910 is subsequently provided. A doming operation 912 is contemplated as being provided after the blank and draw operation 904, after the redraw 906, after the expansion step 908, after the trim operation 914, or after the curl and edge treatment 910. A wash, decoration, and/or coating step 916 is contemplated as being provided after redraw step 906, after expand step 908, and/or after trim step 914.

FIG. 31 depicts a process and method of forming a single panel cup according to an embodiment of the present disclosure. As shown, a process 920 is contemplated that comprises initially providing a coil of stock material (e.g. aluminum). The stock material 922 is formed into an initial cup or container shape via a blank and draw operation 924. The initial cup shape is redrawn at step 926 and a trim operation 928 is provided at an upper (i.e. lip) end of the cup. A curling or edge treatment step 930 is provided. The cup is expanded at step 932. A finishing operation 933 is contemplated and the finishing operation 933 comprises a washing step 934, a decorating step 936, application of at least one bottom coat 938, and an IC spray 940. A rinse and/or inspection process is further contemplated as occurring after the finishing operations 933 and 932. A doming operation 942 is contemplated as being provided at various steps in the process including, for example, after the redraw step, trim step, edge treatment step or expansion step.

FIG. 32 depicts various additional methods 950, 952, 954 of forming a tapered cup according to embodiments of the present disclosure. As shown, the methods contemplate the provision of a coil or quantity of stock material. In embodiments where a large coil of material is provided (including but not limited to the embodiments of FIG. 32 ), it is contemplated that at least one of an unrolling and cutting operation (not shown in FIG. 32 ) is performed to produce a blank or disc of material from the coil. Each of the embodiments of FIG. 32 , a blank and draw operation 956 is provided to form an initial cup shape. At least one redraw operation 958 is provided on the initial cup shape. The cup is then provided in a bodymaker at step 960. The bodymaker is contemplated as ironing the redrawn cup to reduce wall thickness and/or increase the height of the cup. This reduces the amount of incoming metal in the initial blank and coil gauge to reduce costs. In the first 950 and third 954 embodiments, an expansion step 962 is provided after the bodymaker step 960. In a first embodiment 950, a curl and edge treatment 964 is then provided. In a second embodiment 952, a curl and edge treatment 964 is provided after the body maker and the cup is then expanded at step 962. A third process 954 contemplates the provision of a trimming step 966 after expansion 962 and prior to a curl and/or edge treatment step 964. Doming operations 968 and/or washing, coating and decorating steps 970 are contemplated as being provided at various points in the processes.

FIG. 33 depicts a process and method of forming a single panel cup according to an embodiment of the present disclosure. As shown, a process 980 is contemplated that comprises initially providing a coil of stock material (e.g. aluminum). The stock material 982 is formed into an initial cup or container shape via a blank and draw operation 984. The initial cup shape is redrawn at step 986 and a bodymaker operation 988 is provided. The bodymaker is contemplated as reducing wall thickness and/or increasing container height to meet customer and product requirements. A trim operation 990 is provided or performed at the upper edge of the cup. A curl and/or edge treatment is provided 992. The cup is expanded at step 994. A finishing operation 1008 is contemplated and the finishing operation comprises a washing step 998, a decorating step 1000, application of at least one bottom coat 1002, and an IC spray 1004. A rinse and/or inspection process is further contemplated as occurring after the finishing operation 994. A doming operation 1006 is contemplated as being provided at various steps in the process including, for example, after the redraw step, trim step, or edge treatment step. A washing, decorating and/or spraying step 1008 is contemplated as being provided after the trimming step 990 and/or after the edge treatment step 992.

FIG. 34 depicts formation processes for tapered cups according to various embodiments of the present disclosure. As shown, a stock material is initially provided in each process. A cup is initially formed by at least one blank and draw operation at step 1012. The initial cup form is provided in a bodymaker at step 1014. The bodymaker is contemplated as reducing wall thickness and/or increasing container height to meet customer and product requirements. In some embodiments, methods are provided wherein the cup is expanded 1046 after being provided in the bodymaker. In a method of one embodiment, a curl and/or edge treatment 1018 is provided after expansion. A second embodiment is contemplated wherein a curl and/or edge treatment 1018 is provided after a bodymaker process 1014, and the cup is expanded at step 1016 after the curl and/or edge treatment. In a third embodiment, a trimming operation 1020 is provided between expansion 1016 and a curl or edge treatment step 1018.

Various embodiments of the present disclosure contemplate the provision of a dome forming step 1022 and/or washing and decorating steps 1024. Embodiments of the present disclosure including but not limited to those of FIG. 34 contemplate that these steps can be performed at different points or stages of a manufacturing and forming process.

FIG. 35 depicts a forming process for a tapered cup according to an embodiment of the present disclosure. As shown, a process 1030 is provided wherein a coil of material is initial provided 1032. The material is formed into an initial cup shape or form at step 1034. The initial cup shape 1034 is provided in a bodymaker at step 1036. An upper edge portion of the cup is trimmed at step 1038. A curl and/or edge treatment is provided to remove a sharp or irregular upper edge at step 1040. The cup is then expanded at step 1042 according to tools and methods shown and described herein. A doming operation 1043 (indicated by triangles in FIG. 35 ) can be performed at various stages in the process. A finishing process 1044 is further contemplated with various optional steps including, for example, a washing step 1046, a decorating step 1048, a bottom coating step 1050, and a spray coating step 1052. The finishing process can also be provided between steps 1038 and 1140 and/or between 1140 and 1042. Dome process 1043 is contemplates as occurring after steps 1036, 1038, 1040, and/or after 1042.

FIG. 36 is a cross-sectional elevation view of an upper portion of a container 1100. The container 1100 comprises multiple sections 1102 a, 1102 b, 1102 c. The sections may comprises different arrangements, wall angles, thicknesses, etc. as shown and described herein. As shown in FIG. 36 , the container 1100 comprises an interior 1104 and an exterior 1106. As shown, an upper edge 1108 of the cup 1100 is cut at a ninety-degree angle to provide a cut surface that is substantially parallel to a horizontal axis X. Alternatively, it is contemplated that the upper edge 1108 of the cup 1104 can be trimmed or cut at an oblique angle including, for example, an angle A of approximately 135 degrees as shown in FIG. 36 .

FIG. 37 is a cross-sectional elevation view of an upper portion of a container provided with a curl. Various cup and curl features are shown in FIG. 37 . The container comprises an interior and an exterior. As shown, the curl is provided as an inward curl wherein a distal end of the curl is provided proximal an interior portion of the container. A first wall portion 1116 a is provided, and a second wall portion 1116 b extends upwardly at an angle 1118, referred to herein as a neck angle C. The second wall portion 1116 b extends to the curl comprising an upper outer curl radius H, a curl top D, an upper outer curl radius G, a lower outer curl radius, and a tuck portion T. The curl comprises a curl height B, a curl width E. The curl height is contemplated as being between approximately 0.050 inches and 0.200 inches, and preferably about 0.092 inches. The curl width is contemplated as being between approximately 0.050 inches and 0.20 inches, and preferably of about 0.106 inches.

FIG. 38A is a perspective view of a synchronized screw tooling arrangement to form a curl in cups of the present disclosure. As shown, a plurality (four) of rollers 1200 are provided that are operable to be provided external to a container lip or edge. The tooling spins around an axis to form a curl. FIG. 38B is a plan view of a rollers 1200 provided with reference with a container 1202. As shown the roller 1200 surround a cup 1202. The cup 1202 may rotate slightly but is not required to rotate to form a curl. Arrows 1204 are provided to indicate a direction of rotation of the screw-type roller 1200. It is contemplated that the cup 1202 is moveable in the Z-direction (i.e. into the page). FIG. 38C depicts a roller system according to another embodiment of the present disclosure wherein rollers 1200 rotate in the direction indicated by the arrows 1204 and wherein cup 1202 is stationary. The rollers 1200 spin on their axis and are also operable to rotate around the cup as indicated by rotation arrows 1206 to form a curled lip on a cup.

In some embodiments, tooling is provided that comprises with a number of rollers that come into contact with the edge of the metal and/or metal surfaces in order to bend and control movement into a particular form or shape. The roller geometries can be the same or different within one operation. Rollers can vary from 3 up to and including 32 rollers per operation. This is based on diameter, metal thickness, hoop strength, coatings, roller geometry/geometries, speed of the spindle (RPM), product height change, speed of stroke, and acceleration/deceleration of operation. In cases where multiple curl operations, rollers may have the same, different, or a combination of geometries. Subsequent to the 1^(st) curl operation, a controlled tuck can achieve a particular profile. This may be referred to shaping, reprofiling, throttling, curling, tucking, rolling, and smoothing.

A 360 degree tool contacts the container in one motion to achieve a particular profile. This could create the curl, lug, profile. If multiple hits are used, such an operation could be achieved within a transfer press or similar machine.

Once a rounded, outward facing curl is established this operation forms a established profile. The edge can be pushed up tight to conjoining or with slight spacing within the curl space. The outer diameter, curl height, and radii are typically controlled to allow for a particular geometry. Once the curl is formed, but not allowing the cut edge to touch the surface of the container, a controlled expansion of the container pushes the metal of the container to meet the curl. A “curl & trim” is contemplated as occurring within one stroke or draw within a machine. The metal is moved to a particular “flanged” form prior to removing a ring of metal. In a curl & trim, the curl forming process comprises two or more operations. During one cycle of a machine, the curl will be initiated from 0 degrees to 90 degrees (+/−45 degrees). Once the metal pushes outboard a blade, knife, or shear will cut the edge to a controlled position. The finishing operations will complete the tuck of the trimmed edge to be away from a consumer. The final tuck form can vary and multiple iterations are discussed within this summary.

FIGS. 39A-39C provide various views of cup curls and curl geometries according to embodiments of the present disclosure. Various dimensions and geometries are shown to illustrate certain contemplated embodiments, and it should be recognized that cups of the present disclosure are not limited to the curl geometries depicted or even cups having a curl.

In some embodiments, a cup is provided with an inside diameter of between approximately 35 mm and 110 mm. A curl height 1302 is provided that is between approximately 0.020 inches and 0.200 inches. A neck angle 1304 is provided that comprises an angle of between 0 and 60 degrees. A curl diameter 1305 is between approximately 35 and 113 mm, and a curl width 1306 is contemplated as being between 0.020 inches and 0.200 inches. A lower outer curl radius 1308 comprise a radius of between approximately 0.01 inches and 0.100 inches. An upper outer curl radius 1310 comprises a radius of between approximately 0.010 inches and 0.100 inches. A lower inner curl radius 1312 comprises a radius of between approximately 0.010 and 0.100 inches. It will be recognized, however, that these dimensions and ranges of dimensions are provided to illustrate contemplated embodiments. Cups and methods of forming cups of the present disclosure are not limited to any particular dimension or proportion.

FIG. 40 depicts various different curl shapes contemplated by embodiments of the present disclosure. As shown, curls of the present disclosure are contemplated as comprising various shapes, arrangements, orientations, and dimensions.

Various features and embodiments of a metal cup have been provided herein. It will be recognized, however, that various features are not necessarily specific to certain embodiments and may be provided on any one or more embodiments. The present disclosure and embodiments provided herein are not mutually exclusive and may be combined, substituted, and omitted. The scope of the invention(s) provided herein is thus not limited to any particular embodiment, drawing, or particular arrangement of features.

While various embodiments of the present disclosure have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and alterations are within the scope and spirit of the present disclosure. Further, the invention(s) described herein are capable of other embodiments and of being practiced or of being carried out in various ways. In addition, it is to be understood that the phraseology and terminology used herein is for the purposes of description and should not be regarded as limiting. The use of “including,” “comprising,” or “adding” and variations thereof herein are meant to encompass the items listed thereafter and equivalents thereof, as well as, additional items. 

What is claimed is:
 1. A method of forming a metal container, the method comprising: providing a coil of material from which a cup is to be formed; cutting a blank from the coil of material; forming a cup from the blank of material; performing a redraw operation on the cup; providing the cup to a bodymaker; performing at least one of a doming operation and a finishing step subsequent to providing the cup to the bodymaker; expanding at least a portion of the diameter of the cup; and performing at least one of a doming operation and a decorating step subsequent to expanding the cup to form the container.
 2. The method of claim 1, wherein the cup is formed by a blank and draw operation.
 3. The method of claim 1, wherein the cup is expanding by one or more dies.
 4. The method of claim 1, further comprising performing at least one of a curl and an edge treatment at an open end of the cup.
 5. The method of claim 4, wherein the at least one of a curl and an edge treatment comprises a forming a curl subsequent to the expanding step.
 6. The method of claim 1, wherein the finishing step comprises at least one of washing, decorating, coating, rinsing, and inspecting the cup.
 7. The method of claim 6, and wherein the method comprises at least two finishing operations.
 8. A method of forming a metal container, the method comprising: providing a coil of material from which a cup is to be formed; cutting a blank from the coil of material; forming a cup from the blank of material; performing a redraw operation on the cup; providing the cup to a bodymaker; performing at least one of a doming operation and a finishing step subsequent to providing the cup to the bodymaker; expanding at least a portion of the diameter of the cup; and forming a curl at an open end of the cup, wherein the curl comprises an inward curl wherein a distal end of the curl is provided proximal an interior portion of the container.
 9. The method of claim 8, wherein the inward curl comprises a tuck portion comprising a substantially linear portion at a distal end of the curl.
 10. The method of claim 8, wherein the inward curl comprises a curl height and the curl height is between approximately 0.050 inches and 0.200 inches.
 11. The method of claim 8, wherein the inward curl comprises a curl width and the width is between approximately 0.050 inches and 0.20 inches.
 12. The method of claim 8, wherein the inward curl is formed using a screw-type roller.
 13. The method of claim 8, wherein the cup is expanded using one or more dies.
 14. The method of claim 8, wherein a finishing step is performed prior to forming the inward curl and wherein the finishing step comprises at least one of washing, decorating, coating, rinsing, and inspecting the cup.
 15. The method of claim 8, wherein the material comprises aluminum.
 16. A method of forming a metal container, the method comprising: providing a coil of material from which a cup is to be formed; cutting a blank from the coil of material; forming a cup from the blank of material; performing a redraw operation on the cup; providing the cup to a bodymaker; performing at least one of a doming operation and a finishing step subsequent to providing the cup to the bodymaker; expanding at least a portion of the diameter of the cup; and forming a curl at an open end of the cup and wherein the curl comprises an inward curl.
 17. The method of claim 16, wherein the cup is formed by a blank and draw operation.
 18. The method of claim 16, wherein the cup is expanded by one or more dies.
 19. The method of claim 16, further comprising performing an edge treatment at an open end of the cup.
 20. The method of claim 19, wherein the edge treatment comprises forming the curl subsequent to the expanding step. 